Technical Training

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ABB LIMITED
Technical training
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To request our current list of our
open courses or for any other
training query, please email:
contact@gb.abb.com and we will be
happy to help you.
A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G TECHNICAL TR AINING 3
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Contents
Introduction 54 Process Safety Management (PSM)

04 An introduction to ABB best practice
05 Our approach to technical training 56 SIL awareness for control /
06 In-company courses or open dates electrical technicians
07 ABBreviations
08 Booking and contacts A sset integrity
10 Meet some of our tutors 60 Design and operation of piping
12 Course index systems
62 Essentials of pressure systems
Process safety 64 Mechanical integrity - lessons
16 Achieved SIL from process industry incidents
18 Advanced hazard assessment 66 Mechanical legislative awareness
techniques for SIL determination 68 Risk Based Inspection (RBI) and
20 Advanced HAZOP for HAZOP Non-Intrusive Inspection (NII)
leaders
22 An engineers guide to DSEAR Maintenance and reliability
24 Area classification 72 Failure Modes Effects and
26 ATEX / DSEAR for mechanical Criticality Analysis (FMECA)
technicians 74 Introduction to reliability
28 Deep dive audits and assessments workshop
30 Effective alarm management - 76 Root Cause Analysis (RCA)
the practitioners course 78 Shutdown, turnaround and
32 Electrostatic ignition hazards - outages management
assessment and control
34 Hazard study awareness Other
36 Hazard study leaders 82 Construction, Design and
38 Human factors in incident Management (CDM) awareness
investigation 84 Project management in the
40 Human factors in the workplace process industries
42 Human reliability analysis workshop
44 IEC 61508 / 61511 and SIL
determination
46 Layer of Protection Analysis (LOPA)
48 Management of Change (MoC)
50 Pressure relief
52 Pressure relief - the practitioners
course
4 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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An introduction to ABB
In high hazard industries, assuring the

ABB has a worldwide safety, integrity, reliability and efficiency
reputation as a leader in of operating assets requires effective
management of risk. In order to make
process safety, integrity robust risk-based decisions, there is a
management and technical need for an appropriate level of
competence relating to design features,
engineering services. modes of deterioration, operation and
maintenance procedures, fitness for
We provide technical consulting and service and human factors. Increasingly
engineering services to improve therefore, professional engineers need to
performance in the areas of compliance, understand such aspects.
operations and engineering to customers
in the chemical, petrochemical, oil & gas, ABB’s technical training for professional
power, pharmaceutical and other process engineers embodies the above and
industries worldwide. encompasses a wide variety of topics
from piping and machines, to electrical
ABB’s approach to improving business and civil, from safety and environmental,
effectiveness through sound personal to reliability and project management.
competence is born of a real need for
technical training of professional
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engineers within high hazard industries. “We have found ABB to be a
We continue to adapt our training
approach to incorporate changes in both
company offering very high
legislation and industry good practices. quality services in a timely,
cost effective and
professional manner. We
look forward to a long term
relationship.”
EHS Manager, BP
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Our approach to technical training
We believe in being flexible and sensitive

All our courses are prepared to specific customer needs. As such, if
and run by experienced these cannot be met by existing course
content we would be pleased to adapt
practicing engineers and these courses to suit individual or
consultants, with many company needs.
years experience. For example:
Some courses are accredited / –– In-house courses delivered at client

recognised by professional bodies such sites present an opportunity for
as: problem-solving workshop sessions,
where specific issues from within the
–– The Institution of Chemical Engineers work place can be worked through
(IChemE) and members will receive a –– Courses can be specifically developed
discount on all accredited courses using a range of topic modules, to suit
–– The Chartered Institute of Ergonomics client needs
and Human Factors (CIEHF) –– One-to-one coaching is also available,
–– Cogent Skills, ABB is an assured tailored to suit the needs of the
provider individual
–– In-house courses can be tailored to
Chartered Institute
include customer specific procedures
of Ergonomics
& Human Factors etc.
RECOGNISED COURSE
These courses have been successfully

delivered for many years across all
The courses are presented in an industry sectors including chemical,
interactive manner by presentation and petrochemical, oil & gas, power,
discussion of the key issues. Case studies pharmaceutical and other process
based on actual events and exercises are industries.
included to allow delegates to put the
new ideas they have learned into practice.
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In-company courses or open dates
We understand that not all companies

If you have a specific team operate in the same way, so we can work
that you wish to train at a with you to identify your particular
competency needs, then customise
given time, our trainers can courses or even combine multiple courses
come to your premises, or into a structured sequence, i.e. to be part
of your graduate development
any other venue you wish to programme or your on-going engineering
use. development programme.
We also run regular open courses

Our in-company courses are ready to be
scheduled frequently across the year, in
delivered off-the-shelf, or can be tailor-
locations all over the UK. These courses
made to your organisation’s particular
also offer the opportunity for delegates
needs, policies or even installations, to
to temporarily get away from their busy
ensure that the right message is
office and network with industry peers.
communicated to your people.
Our up-to-date course schedule is

available online at:
www.abb.com/uk/consulting/training
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ABBreviations
FMECA
Failure Modes Effects
and Criticality Analysis
RCA
Root Cause Analysis
SIL
Safety Integrity Levels
LOPA
Layer of Protection Analysis
ATEX HAZOP
ATmospheres EXplosives HAZard and OPerability study
DSEAR
Dangerous Substances and
Explosive Atmospheres Regulations
SIF PSM
Safety Instrumented Functions Process Safety Management
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Booking and contacts
For course enquiries, contact our

Our team is happy to work training administrator:
with you to understand your
individual needs and find Jackie Kendall
the best training solution +44 (0)1642 372 121
jackie.kendall@gb.abb.com
for your people.
Alternatively you can visit our website:
www.abb.com/uk/consulting/training
where you can see further details, dates
and locations of all of our courses along
with links to book your place online.
B O O K I N G A N D C O N TA C T S 9
Reduced terms and conditions It may be necessary for reasons beyond

For full terms and conditions follow this the control of the organisers to cancel
link: the event, alter the content, change the
www.abb.com/uk/consulting/training timing of the programme, or the listed
and select the booking and contacts link. speaker(s).
Cancellations made up to 28 days prior to Please note: For courses held in hotel
the event will be subject to an venues: If you request overnight
administration fee of £50. Cancellations accommodation at the hotel and then
made 27-14 days prior to the event will be choose to cancel less than 2 weeks prior
subject to a cancellation fee of 50%. to the event, then it is your responsibility
Cancellations made thereafter will be to pay any cancellation fees. Any event
subject to the full event fee, however a fee already settled will be refunded if the
substitute delegate can be named at any event is cancelled by ABB. Travel
time. expenses will not be covered.
Prices apply to bookings made prior to For courses held in ABB locations: ABB
31st December 2018. Payment is due at withholds the right to cancel the event up
the end of the month following the date to one week before the event. Therefore,
of the training course. Accommodation is we recommend any accommodation and
not included in the prices. travel bookings are flexible.
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Meet some of our tutors
Graeme Ellis
Specialist Safety Consultant
Graeme has over 33 years experience in —

the process industry, originally training
as a chemical engineer and now a Fellow
“I derive great pleasure from
of the IChemE and member of the Energy the opportunity to pass on
Institute Process Safety committee. He
started training on ICI’s well recognised
best practices and
hazard study awareness course in the experiences gained across
mid 1990’s, and has since been involved
in training for hazard study leaders, static
all sectors of the process
hazards and process safety in design. industry, hopefully playing a
More recently Graeme was involved on
part in making our industry
the ‘expert panel’ developing training a safer place to work.”
standards for process safety, and has
since delivered training to senior
—
executives and site based staff through “Each group of delegates
the National Skills Academy.
presents new challenges,
trying to understand their
level of experience and
adapting the delivery to
best meet their needs and
to make the course as
interesting and interactive
as possible.”
M E E T S O M E O F O U R T U TO R S 11
Chris Flower
Chemical Engineering Specialist
Chris has over 15 years of process —

engineering experience. Throughout his
career he has been involved in pressure
“Training is a vital part of
relief be it, designing new systems, our industry, passing on
reviewing existing systems or validating
systems designed by others across the
good practice as well as the
whole range of process industry sectors. real life experiences that
Chris has led the pressure relief course
cannot be captured in
for more than 10 years training over a 100 guides and standards.”
delegates a year.
—
“Training is a rewarding
experience and we try to
have as much fun as
possible while spending
three intensive days.”
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Course index
Process safety courses In-company Open

Achieved SIL X X
Advanced hazard assessment techniques for SIL determination X X
Advanced HAZOP for HAZOP leaders X X
An engineers guide to DSEAR X X
Area classification X X
ATEX / DSEAR for mechanical technicians X
Deep dive audits and assessments X X
Effective alarm management - the practitioners course X X
Electrostatic ignition hazards X
Hazard study awareness X X
Hazard study leaders X X
Human factors in incident investigation X
Human factors in the workplace X X
Human reliability analysis workshop X X
IEC 61508 / 61511 and SIL determination X X
Layer of Protection Analysis (LOPA) X X
Management of Change (MoC) X X
Pressure relief X X
Pressure relief - the practitioners course X X
Process Safety Management (PSM) - best practice X X
SIL awareness training for control / electrical technicians X X
COURSE INDE X 13
Asset integrity courses In-company Open
Design and operation of piping systems X X
Essentials of pressure systems X X
Mechanical integrity - lessons from process industry incidents X
Mechanical legislative awareness X X
Risk Based Inspection (RBI) X X
Maintenance and reliability courses In-company Open
Failure Modes & Effects and Criticality Analysis (FMECA) X X
Introduction to reliability workshop X
Root Cause Analysis (RCA) X X
Shutdown, turnaround and outages management X
Other In-company Open
Construction, Design and Management (CDM) awareness X
Project management in the process industries X
New for 2019 In-company Open
Asset integrity X X
Essentials of rotating machines X X
Essentials alarm management X X
Electrical awareness X X
14
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Process safety
15
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Achieved Safety Integrity Level (SIL)
Process Industries rely upon the

In-company / open course Yes / Yes
performance of Safety Instrumented
Duration 2 days
Functions (SIFs) to protect and maintain
operating assets. Engineers and designers
are required to calculate the probability of –– Apply correct formulae for serial or
failure of these SIFs to be able to express parallel instrument configurations
this performance as a SIL. –– Derive instrument failure rates from
commonly available sources
ABB has created this two day course for –– The benefits and disadvantages of
engineers or designers who require more manufacturers certificates
detailed training in the concepts and –– Appreciate the complexities of a ‘human
principles that underpin the IEC 61511 in the loop’
functional safety standard and its use for –– What checking and approval is needed for
calculating the SIL of a proposed or existing different Safety Integrity Levels
SIF. –– Calculate the SIL
What the course will cover? Course leader

The training course is structured around Paul Lucas is a principal safety consultant at
instruction and workshops that initially ABB with over 35 years’ experience of real-
explain the underlying concepts of SIL time computing and instrumented safety in
calculation demonstrated on simple SIFs, the process chemical, oil & gas and
then progress through more complicated pharmaceutical sectors. He designs and
designs and techniques that are required delivers ABB’s training courses and
for higher Safety Integrity Levels. seminars on the practical implications for
end users, system integrators and
Who will benefit and what will they gain? instrument technicians in the use of the
The course is aimed at engineers and IEC61511 functional safety standard, on
designers involved in calculating or managing Functional Safety and detailed
verifying the performance of new or design of safety instrumented functions. In
existing safety instrumented functions. The recent years, Paul has completed a Master’s
course has plenty of workshops to enable degree in Ergonomics and Human Factors
delegates to practice using the formulae on to gain theoretic background in support of
ever increasing complex examples. many years operational experience in the
assessment and analysis of Human Factors
Following the course you will be able to: in Safety Critical tasks, including Task
analysis and Human Error Analysis (HEA).
–– Understand the concepts underpinning
SIL calculation
–– Identify what information is essential
before starting the SIL calculation
ACHIE V ED S A FE T Y INTEGRIT Y LE V EL (SIL) 17
Day 1 agenda*
Registration and coffee
Introduction
SIL as part of functional safety
–– Why do we need functional safety and safety instrumented systems?
–– Functional safety standards; IEC61511 and IEC61508
–– ‘Three Steps’ to SIL; SIL Determination, Achieved SIL, Operations and Maintenance
Setting the target SIL
–– Risk and risk reduction
–– Reminder of hazard identification and SIL determination
Safety requirement specification
–– Information to be specified to design group or external company
Designing a Safety Instrumented Function
–– Safe and dangerous failures
–– The relationship between instrumentation and SIL
–– Use of basic calculations
–– Humans and alarms as part of Safety Instrumented Functions
–– Importance of dangerous failure rates for instrumentation
–– Instrument data sources and instrument certificates
Summary and conclusions
Close
Day 2 agenda*
Review of Day 1
Testing as part of the SIF Design
–– High and low demand rate safety functions
–– Time to test and errors introduced during testing
–– Relationship between PFDavg, instrument failure rates and test intervals
Advanced architectures (1oo2, 2oo3) and constraints
–– Calculations
–– Hardware fault tolerance
–– Diagnostic coverage and safe failure fraction
–– More on manufacturers certificates
–– Systematic controls
–– Common cause and common mode failures
–– Sharing equipment between SIF and Control system
–– Testing final elements and partial testing
Installation and commissioning
–– Validation, verification, audits and functional safety assessment
Operate and Maintaining the Safety Instrumented Functions
–– Proof testing requirements
–– O verrides and bypasses
–– Maintenance and modification
–– Importance of recording and reviewing demands and test results
Review and feedback
Close
*ABB reserve the right to amend the course agenda.
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Advanced hazard assessment
techniques for SIL determination
Management of risk and the demonstration
of appropriate risk reduction measures are
Duration 5 days
becoming increasingly important in
industry today. This can be relevant to
compliance with aspects of legislation, such –– Basic human error assessment
as COMAH, and in the application of –– Applying basic SIL and hazard assessment
standards such as IEC 61508 and IEC 61511. in a variety of situations to help in making
more effective and cost effective
This course is designed for those who need decisions
to understand the causes and sequence of
failure that can lead to significant This course is also suitable as a basic
hazardous events occurring and be able to qualification for those wanting to become
identify the key contributors to the level of hazard and reliability analysts.
risk - to people, business or the
environment. Who will benefit and what will they gain?
The effective use of the techniques allows
Topics include: questions to be answered in the areas of
safety, health and environment; asset
–– Calculation of hazardous event management and maintenance; loss
frequencies prevention; new investment. Typical
–– Assessment of risk reduction from attendees would be:
protective systems and Safety Integrity
Levels (SIL) –– Process design engineers
–– Criteria for tolerable levels of risk –– Electrical, control and instrument
–– Assessment of demand frequence on engineers
protective systems –– Safety managers and advisors
–– Works or technical managers with
What the course will cover? responsibility for managing risk
On completion of the course you should be –– Leaders of HAZOP studies
able to demonstrate a working knowledge
of SIL and hazard assessment including: Typical attendees would probably have:
–– Some experience of design and plant
–– Logical analysis, using fault tree operation
techniques of scenarios leading to –– An analytical and structured approach to
hazardous events problem solving
–– Use of data and its application to predict
the likelihood of a hazardous event
–– Development of practical hazard criteria
–– Handling of dependent or common mode
failures
NOTE: This course was previously titled SIL determination
and hazard assessment.
A D VA N C E D H A Z A R D A S S E S S M E N T T E C H N I Q U E S F O R S I L D E T E R M I N AT I O N 19
Syndicate topics –– Use of minimum cut-sets to analyse

–– Working with logic gates complex protective systems
–– Use of the basic techniques to assess the –– Risk calculation for various operator
potential frequency of hazardous events situations
–– Logic diagram development and effect of
proof testing Course leader
–– Logic diagram development and effect of Gaynor Woodford-Phillips is a safety
elements common to control and specialist for ABB and specialises in
protective systems technical process safety which includes
–– Logic development and use of data carrying out target SIL assessments,
–– Use of event trees quantified risk assessments (QRA) and
–– Failure rate for multiple plant items - consequence modelling. Gaynor is a Fellow
development of logic of the Institute of Chemical Engineers with
–– Use of truth tables in analysing different over 25 years’ experience in project design,
plant arrangements operations support and line management in
–– Cost effective decision taking in the petrochemical and chemical industries.
controlling hazards
–– Logic diagram development and the
relative merits of shared elements and
independent control and protective
systems
Day 1 agenda*
–– Registration and coffee –– Risk assessment
–– Introduction –– Consequence assessment
–– International standards - IEC 61508/61511 –– Layer of Protection Analysis (LOPA)
–– Risk and criteria –– Syndicate exercises
Day 2 agenda*
–– Event tree analysis –– Syndicate exercises
–– Reliability concepts of elements and states
–– Guided exercise - development of fault trees to
assess hazards
Day 3 agenda*
–– Use and collection of reliability data –– Syndicate exercises
–– Trip system overview
Day 4 agenda*
–– Protective systems mathematics and assessment –– Failure dependency - key issues regarding
techniques dependent failure
–– Limiting factors in PFDawg - common cause –– Syndicate exercises
failures etc. –– Intro to hazard study 2 quantification exercise
Day 5 agenda*
–– Hazard study 2 syndicate exercise - applying the principles learned over the week
IChemE members receive discount.

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Advanced HAZOP for HAZOP leaders
Are you looking to improve your skills as a

HAZOP leader?
Duration 3 days
Do you want to become a more competent

HAZOP leader? ABB has also conducted thousands of
HAZOP studies for many clients across
Are you looking for some refresher training many industrial sectors. They have a large
on the HAZOP methodology? pool of experienced HAZOP leaders.
Are you looking to continuously improve the What the course will cover?
way you conduct HAZOP studies? This course has been developed by ABB’s
experienced leaders by reflecting upon
Do you want HAZOP studies to be more those years of experience. ABB have
effective? identified both good and best practice
techniques to further enhance the
Are you interested in how best to apply the methodology and develop advanced HAZOP
HAZOP technique to an existing process techniques. Employing advanced HAZOP
and keep the HAZOP evergreen through the techniques ensures a greater depth of
re-validation process? review is achieved, links to LOPA studies are
built, good action specification is
The HAZOP methodology is a well implemented, links to alarm management
established technique used throughout and integrity management. Traditionally the
industry for hazard identification and risk HAZOP technique has been applied during
assessment. The technique was originally the detailed design stage of a project. This
developed in the 1960’s by ICI and guidance course will show how the advanced HAZOP
on its use was first published in the 1970’s technique can be applied retrospectively to
following the Flixborough disaster where an an existing process and how the HAZOP
inadequately designed modification led to a study can be re-validated and kept
large vapour cloud explosion killing 28 evergreen.
people. The technique is formally
recognised by many regulators in many Who will benefit and what will they gain?
parts of the world and details of the HAZOP The course is aimed at reflecting upon
methodology are outlined in the existing guidance and providing new
internationally recognised standard (IEC: improved guidance for experienced leaders.
61882 - Hazard and operability studies The course is also aimed at providing
{HAZOP studies} - application guide). refresher training for experienced leaders.
Note that this course builds upon ABB’s
ABB has provided training in the HAZOP existing four day hazard study leader’s
technique for more than 20 years and course. The 4 day course or suitable
trained hundreds of personnel. alternative is a precursor to the advanced
HAZOP training course.
A D VA N C E D H A ZO P F O R H A ZO P L E A D E R S 21
Benefits Course leader

–– Detailed guidance on good / best practice Graeme Laughland is a safety specialist for
techniques ABB and specialises in hazard identification
–– Opportunity to evaluate good / best and risk assessment and PSM auditing.
practice techniques through workshops Graeme is a chemical engineer with 30
–– Refresher training for experienced HAZOP years’ industrial experience gained in
leaders design, operations and process safety
–– Improved consistency of approach to consultancy. In addition to consultancy
HAZOP studies assignments he tutors on a range of
–– Improved competency of HAZOP leaders process safety courses and has presented
–– Improved quality and output from HAZOP papers at a number of international
studies conferences.
Agenda*
Introduction
The need for HAZOP studies and improvement - initial project, retrospective, re-validation
Planning and preparation
–– Terms of reference workshop
–– HAZOP node definition and selection
–– HAZOP node workshop
Conducting the HAZOP
–– How to fill out the HAZOP table
–– Risk ranking
Recommendations
–– How to write effective recommendations - workshop
Retrospective and re-validation HAZOPs
Human factors and the human HAZOP
–– Human HAZOP workshop
HAZOP and link to SIL determination (e.g. FTA, LOPA) studies
HAZOP nodes for complex systems such as flares , drainage and distribution systems
Report writing
HAZOP studies and the link to asset / mechanical integrity
HAZOP studies and the link to alarm management
Review of the course
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An engineers guide to DSEAR
Employers have now been living with the

Dangerous Substances and Explosive
Duration 1 day
Atmospheres Regulations (DSEAR) since
2002. However, there remain a number of
questions regarding the best route to What the course will cover?
compliance in a pragmatic and cost –– Properties of flammable materials
effective way. –– DSEAR risk assessment
–– Area classification
ABB have helped a large number of –– Hazardous area equipment
customers with DSEAR issues across a –– Certification and retrospective
number of sectors including oil and gas, assessment of mechanical equipment
printing, pharmaceutical API production,
pharmaceutical research and development, Who will benefit and what will they gain?
cement, power, steel making and chemicals. Industry engineers and managers with
responsibility for any element of the
This course provides an overview of management of areas where there could be
different aspects of DSEAR required to flammable or explosive atmospheres.
operate a safe process and comply with the
requirements of the legislation. It will be Course leader
presented by an experienced safety Peter Hodgson is a safety specialist with
consultant with input from a leading over 10 years of experience in the ATEX and
manufacturer of certified equipment in the DSEAR field, including hazardous area
UK and an operator of a complex and classification, DSEAR compliance, and
potentially hazardous flammable process. mechanical equipment risk assessment, in
many industries including oil & gas,
You will learn the fundamentals of DSEAR chemicals, paints and coatings, material
and take away an action plan to check your handling, pharmaceuticals and offshore.
facilities against the requirements of the
legislation and be able to identify potential
improvements in your current compliance
strategy.
A N E N G I N E E R S G U I D E TO D S E A R 23
Course agenda*
Introduction and overview of legislation
Properties of flammable materials
DSEAR compliance in the chemical and pharmaceutical industries
Coffee / tea
Hierarchy of control and area classification
Lunch
Area classification exercise
Overview of certified equipment
Coffee / tea
ATEX certification for fans
Retrospective certification for mechanical equipment
Close
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Area classification
What is your process? Can you have

combustible / flammable atmospheres?
Duration 2 days
Have you identified the likelihood of a

combustible or flammable atmosphere –– Introduction to BS EN 60079-10-1:2015
occurring? the British Standard for area classification
relating to gases and vapours. The scope
As part of the overall assessment have you a of this standard is addressed, in particular
documented area classification? the grading of releases and the effect of
ventilation
The classification of hazardous areas is an –– The course provides an overview of two
integral part of the overall risk assessment widely used codes, EI15 edition 4 and
process required under Regulation 7 of the SR25 edition 2 including syndicate
Dangerous Substances and Explosive exercises
Atmospheres Regulations 2002 (DSEAR) –– Introduction to BS EN 60079-10-2:2015
and Regulation 9 of the Prevention of Fire the British Standard for area classification
and Explosion and Emergency Response relating to dusts. The scope and use of
Regulations 1995 (PFEER). this standard is addressed, complete with
a syndicate exercise
Its purpose is to define the extent,
frequency and duration of an explosive Who will benefit and what will they gain?
atmosphere (the zone). The zone in turn The course should suit recent graduates
defines the requirements for the selection and experienced staff with operations,
of equipment and protective systems so as process, engineering and safety
to control sources of ignition. responsibilities.
Compliance with DSEAR is mandatory for On completion you should be able to:
any onshore operator handling dangerous
substances and PFEER for any operator of –– Understand why area classification is
fixed offshore installations. carried out
–– Understand the principles of area
What the course will cover? classification
–– Introduction to DSEAR (2002) and in –– Understand the steps in the area
particular the requirements for area classification procedure
classification and selection of equipment –– Identify the grades of release and how
to avoid ignition sources they relate to zoning
–– The flammability of gases, vapours and –– Appreciate the industry codes available
dusts and how they relate to area that can be used to establish the extent of
classification zones
A R E A C L A S S I F I C AT I O N 25
–– Understand the requirements for Course leader

selection of equipment to be installed in Peter Hodgson is a safety specialist with
potentially explosive atmospheres over 10 years of experience in the ATEX and
–– Join an area classification meeting and DSEAR field, including hazardous area
work under the direction of an classification, DSEAR compliance, and
experienced practitioner mechanical equipment risk assessment, in
many industries including oil & gas,
The training method chemicals, paints and coatings, material
Lecture presentations are supplemented handling, pharmaceuticals and offshore.
with case studies and syndicate exercises.
Day one agenda*

Introduction to DSEAR (2002) and how area classification plays an integral part in assessing the risk to
personnel
The flammability of gases, vapours and dusts and how they relate to area classification equipment for
use in hazardous areas
–– New equipment
–– Existing installed equipment
BS EN 60079-10-1:2015 (Gases & Vapours) - British Standard ‘Classification of hazardous areas’.
–– Introduction to this standard
–– Scope and use
–– Procedure
Use of an ‘Industry Code’ (1).
–– The institution of Gas Engineers (IGE/SR/25) edition 2 ‘Hazardous area classification of natural gas
installations’
–– Scope and use
Day two agenda*
Use of an ‘Industry Code’ (2)
–– EI model Code of Practice in the Petroleum Industry, Part 15, edition 4. ‘Area classification code for
installations handling flammable fluids’
–– Overview
–– Structure
BS EN 60079-10-2:2015 (Dusts) - British Standard ‘Classification of areas where combustible dusts are
or may be present’
–– Introduction to this standard
–– Procedure
–– Syndicate exercise using BS EN 60079-10:2
Forum and close

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ATEX / DSEAR for mechanical
technicians
Are your mechanical engineering teams
In-company / open course Yes / No
aware of the requirements of ATEX / DSEAR
Duration 1/2 day
compliance for the equipment installed
within your asset?
With the advent of the ATEX directives there Who will benefit and what will they gain?
are new requirements for the specification, The course will provide a clear
installation, inspection, maintenance and understanding of the best practice
repair of mechanical equipment installed in requirements for mechanical equipment
hazardous areas. ABB is working for operating in potentially flammable
operators in the process industries to atmospheres. The course has been
achieve and maintain compliance for their designed to be of benefit to mechanical
assets. Providing a practical perspective technicians and supervisory staff. It will
based on real life experience comes also provide other engineering disciplines
naturally. with an overview of the requirements for
mechanical equipment compliance.
What the course will cover?
As part of its overall Dangerous Substances Course leader
and Explosive Atmospheres Regulations Peter Hodgson is a safety specialist with
(DSEAR) compliance programme, an end over 10 years of experience in the ATEX and
user operator will be required to provide the DSEAR field, including hazardous area
facility mechanical technicians with classification, DSEAR compliance, and
awareness training in the ATEX directives mechanical equipment risk assessment, in
and the DSEAR regulations. This short many industries including oil & gas,
course is designed to give you an chemicals, paints and coatings, material
appreciation of the following: handling, pharmaceuticals and offshore.
–– A brief introduction to the ATEX 95 and

137 directives, DSEAR and the equipment
supply regulations
–– An introduction to hazardous area
classification
–– The risk assessment requirements for
existing mechanical equipment
–– Mechanical equipment certification and
marking
–– The purchase of new mechanical
equipment
–– The maintenance and inspection of
mechanical equipment located in
hazardous areas
AT E X / D S E A R F O R M E C H A N I C A L T E C H N I C I A N S 27
Course agenda*
Registration, coffee and bacon rolls
Introduction
–– ATEX Directives, DSEAR and EPS Regulations
–– General requirements and duties
–– Introduction to hazardous area classification
–– Risk assessment of existing mechanical equipment
–– Mechanical equipment certification and marking
Coffee
–– Purchasing new mechanical equipment
–– Maintenance and inspection of mechanical equipment located in hazardous areas
–– Quiz (clarification of learning)
–– Questions and discussion of mechanical equipment compliance issues
Close
—
Deep dive audits and assessments
A practical one day training course for

personnel who want to conduct deep dive
Duration 1 day
audits and assessments of Major Accident
Hazards (MAHs).
This technique is a novel tool which can be
Over recent years the process industries used to help rapidly assess the adequacy of
have experienced many major accidents controls for major accident hazards. The
which have led to higher technical technique focuses on reviewing a facilities
standards and tighter legislative controls. key risks by asking the following 3
Many companies have conducted Process questions:
Safety Management (PSM) systems type
audits and may believe that all is under –– Do we understand what could go wrong?
control. However, incidents continue to –– Do we know what our systems are to
occur and this suggests that more needs to prevent this from happening?
be done. A growing number of –– Do we have information to assure us that
organisations are becoming increasingly they are working effectively?
aware that process safety issues need to be
managed in a risk-based way linked to their The deep dive audit and assessment tool
business needs, but also cost effectively. can help to ensure that a company:
Good PSM must embrace the way in which
people, plant and systems all inter-relate: –– Has control of the key process safety
aspects of the business
–– Plant and equipment must be of an –– Achieves the process safety performance
appropriate design standard / integrity improvements needed
and be adequately maintained –– Spends money on process safety
–– Systems / procedures must be fit for management and improvement in the
purpose and practicable most effective way
–– People must be adequately competent –– Has a consistent commitment to process
and work within a positive cultural safety throughout the business
framework that encourages safe –– Has access to the skills, resources and
behaviour and a belief that any injury, expertise required
harm or damage can be avoided
Deep dive audits and assessments provide The course uses a lively mix of interactive
a thorough streamlined review of the presentations, case study examples and
robustness of barriers protecting against typical findings from ABB’s experience of
major accident hazards and so the using this technique, exercises and videos.
technique differs from a more commonly A workshop is included to help delegates
conducted PSM systems audit. Findings develop a plan for integrating deep dive
provide a clear tangible link to an asset’s audits and assessments into their PSM
key major accident hazard risks. system assurance program.
DEEP DIVE AUDITS AND A SSESSMENTS 29
Who will benefit and what will they gain? –– What plant records to check and things to
The course will be of benefit to personnel look out for on plant tours
who want to obtain assurance with regards –– How to write a deep dive audit and
to the controls of their MAHs using the deep assessment report
dive audit and assessment methodology. –– How to establish a deep dive audit and
The course is of benefit to personnel who assessment program into a company’s
have responsibilities under the COMAH PSM system
regulations for the control of MAHs. ABB’s
experience is that personnel with Course leader
responsibilities for PSM and integrity Graeme Laughland is a safety specialist for
management have the right skill sets and ABB and specialises in hazard identification
are well placed to conduct deep dive audits and risk assessment and PSM auditing.
and assessments. On completion of this Graeme is a chemical engineer with 30
course you will have an understanding of years’ industrial experience gained in
how to: design, operations and process safety
consultancy. In addition to consultancy
–– Conduct a deep dive audit and assignments he tutors on a range of
assessment using ABB’s proven process safety courses and has presented
techniques and methodology papers at a number of international
–– How to plan and prepare for a deep dive conferences.
audit and assessment
–– How to carry out effective interviews with
site personnel
Course agenda*
Introductions and objectives of the day
Buncefield incident
Process safety barriers - their importance and their nature re: verification
Identifying and defining barriers and exercise
Scoping the barrier verification requirements
Planning a deep dive barrier verification study
Conducting a deep dive barrier verification
Exercise scoping barrier verification requirements
Interviewing
Barrier verification as an integral part of monitoring and reviewing PSM arrangements
Path forward workshop
Course review
—
Effective alarm management
The practitioners course
Edition 3 of EEMUA 191 - Are you up to
speed with the latest changes and improved
Duration 3 days
guidance?
Are you confident that your alarm system is supplemented as appropriate by the good
effective? practice guidance contained in EEMUA 191
–– The alarm management lifecycle;
Do you know if your operators are burdened requirements, recommendations and
with too many alarms and how this might good practice for alarm identification,
be improved? specification, design and implementation.
Including human factors and HMI design
Could you miss key safety or environmental –– Alarm system documentation; alarm
alarms during an incident? philosophy, alarm system requirements
specification and master alarm database
Alarm systems themselves need to be –– Setting of performance targets
managed; the alarm system needs to be Managing your alarm system for
configured in a consistent manner so that continuous improvement; the role of
the operator is in a position to take the performance measurement, monitoring
most appropriate action. ABB’s practical and review. Alarm monitoring and logging
approach to alarm management takes you tools. Alarm analysis techniques
through the full alarm lifecycle covering the –– Advanced alarm management, tools and
Projects, Operations and Maintenance techniques, risk / benefit considerations
phases. As well as offering guidance for –– Drivers and benefits for prospective and
alarm specification and design, we will help retrospective alarm rationalisation
you to identify and solve problems with
existing systems such as nuisance alarms. Who will benefit and what will they gain?
While reduced legislative risk continues to This course is suitable for anybody involved
be a major driver, significant financial in the specification, design, operation and
savings can be achieved from a well maintenance of control systems or anyone
designed and maintained alarm system who has an interest in improving their
which provides operators with an effective current alarm system.
tool to deliver operational benefits
including increased up time, higher OEE, On completion you should be able to:
improved maintenance and tighter product
quality. –– Understand why your alarm system
should be managed
What the course will cover? –– Identify and evaluate the associated
–– Standards and guidance; ASM, ISA, HSE, benefits
–– NAMUR. The course is based on the –– Have a good awareness of ISA 18.2 and the
requirements of ISA 18.2, and IEC 62682, latest standard IEC 62682 requirements
EFFEC TIVE AL ARM MANAGEMENT - THE PR AC TITIONERS COURSE 31
and recommendations and the guidance The training method

contained in EEMUA 191 This is a highly interactive course in which
–– Better understand the value and role of lecture presentations are supplemented
alarms with practical examples, case studies, and
–– Develop an alarm philosophy and design individual & group exercises to reinforce the
and implement an alarm schedule / formal learning.
database
–– Apply requirements and good practice to Course leader
the identification, specification and Colin Bartliff is a senior safety specialist for
design of new alarms ABB. He has over 35 years of industry
–– Have an understanding of the need and experience in a variety of roles covering
benefits of performance measurement process, maintenance, project
and what tools are available management, plant commissioning,
–– Have an understanding of the continuous start-up, technical plant / process
improvement cycle for alarm management troubleshooting and latterly holding a
–– Identify nuisance alarms and assemble a leading positon with a leading chemical
toolkit that helps reduce them company. Colin has held a senior position
–– Understand the process, inputs and within ABB, leading several alarm
deliverables from an effective alarm management projects in the UK and abroad.
rationalisation exercise Colin is Hazardous Area (COMPEX) certified
and a qualified Functional Safety TUV
Engineer.
Day one agenda*

Alarm management today Operating envelopes
What is an alarm? Highly Managed Alarms (HMAs) / protective layer
Standards and guidelines Responding to alarms
Roles and responsibilities Alarm system performance targets
Alarm system documentation Alarm management benefits
Day two agenda*
Alarm identification HMI auditable annunciation prioritisation
Rationalisation Enhanced and advanced alarm methods
Design considerations (including worked examples) Management of Change (MoC)
Day three agenda*
Alarm logging and analysis tools Nuisance alarm review
Performance monitoring Alarm shelving
Continuous improvement Bulk rationalisation
Alarm analysis

—
Electrostatic ignition hazards -
assessment and control
A practical one day training course on the
assessment and control of electrostatic
Duration 1 day
hazards in industry.
Electrostatic hazards are common in all Who will benefit and what will they gain?
sectors of the process industries during the The course will benefit delegates from all
handling and processing of flammable industry sectors handling flammable gases,
powders and liquids. Electrostatic sparks vapours or powders.
are capable of ignition of flammable
vapours, gases and powders resulting in Course leader
potential fire and explosion. On average, Graeme Ellis is a specialist safety consultant
one incident relating to static electricity providing PSM related services within the
occurs every day throughout the chemical high hazard process industry. He specialises
industry in Europe. in risk assessment for new processes and
existing plants, inherent safety, fault tree
The Dangerous Substances and Explosive analysis, consequence assessment, basis of
Atmospheres Regulations (DSEAR) came safety development, electrostatic hazards,
into force in July 2003. One important fires and explosions. Graeme is a Fellow of
requirement for compliance is to carry out the IChemE and member of the Energy
an assessment of potential ignition sources Institute Process Safety committee with
including electrostatic hazards. over 33 years experience in the process
industry in design, operational and
What the course will cover? consultancy roles.
–– How static can be generated on your plant
–– How to identify which operations on your
site are most at risk from electrostatic
hazards
–– Options for risk reduction and
management of the hazard
E L E C T R O S TAT I C I G N I T I O N H A Z A R D S - A S S E S S M E N T A N D C O N T R O L 33
Course agenda*
Introduction
Exercise: Petrol station incident
Overview of flammability hazards
Generation of electrostatic charge
Charge accumulation
Exercise: Electrostatic hazard identification
Electrostatic discharges
Ignition risk
Control measures:
–– Avoiding flammable atmospheres
–– Preventing charge generation
–– Earthing and bonding
–– Explosion protection
Exercise: Road tanker loading
Incident case studies
Close
—
Hazard study awareness
A practical one day training course to

provide improved awareness for hazard
Duration 1 day
study team participants.
In addition to catastrophes such as the What the course will cover?

accidents at Flixborough, Bhopal, Seveso The course has modules on the suite of
and more recently at Toulouse, major hazard studies throughout a project cycle
accidents occur almost daily in the chemical plus related process safety topics. It uses a
process industry. ICI invented the hazard lively mix of interactive presentations,
and operability (HAZOP) study in the 1960s worked examples, exercises and videos for
to anticipate hazardous events and ensure both batch and continuous processes.
that suitable protective measures were
included in the process by design. HAZOP Who will benefit and what will they gain?
has become firmly established as an The course will be of benefit to engineering
essential safety tool during the design and operations staff likely to be actively
stage of new processes and significant involved in hazard study teams for new
modifications. Many companies have a suite processes or significant modifications.
of hazard studies carried out throughout
the project process. Those coming under On completion of the course you should
the COMAH Regulations in the UK use their have greater awareness of:
hazard study process to demonstrate that
the risks of their operations continue to be –– A range of hazard study techniques and
as low as reasonably practicable. how these fit into a typical project
programme
A hazard study is a team-based exercise –– Key assumptions and limitations of
and the quality of the result is highly hazard studies
dependent on the standard of leadership –– Their role in the hazard study process
and the contribution of the study team –– Problems that can arise during hazard
members. Whilst the need for the study studies and how the team can help to
leader to be suitably trained and resolve them
experienced is well recognised, the study –– Related topics such as inherent safety,
will be greatly enhanced by team members risk assessment, instrumented protective
who are fully aware of their role and systems and human factors
contribution. The regulatory authorities are
increasingly questioning the competence of
those involved in safety related activities.
This course is aimed at providing a

demonstration that suitable training is
being provided, to be backed up by on-the-
job experience.
H A Z A R D S TUDY AWA R ENE SS 35
Course leader
Graeme Ellis is a specialist safety consultant Graeme is a Fellow of the IChemE and
providing PSM related services within the member of the Energy Institute Process
high hazard process industry. He specialises Safety committee with over 33 years
in risk assessment for new processes and experience in the process industry in
existing plants, inherent safety, fault tree design, operational and consultancy roles.
analysis, consequence assessment, basis of
safety development, electrostatic hazards,
fires and explosions.
Day one agenda*

Learning from accidents:
–– Notable accidents in the process industry –– The changing legislative environment
–– Common causes of accidents
Introduction to hazard studies:
–– Brief history of hazard studies –– Timing of studies in the project lifecycle
–– Legislation and published guidance –– When can hazards be identified - syndicate
–– The 6-stage hazard study process exercise
Early hazard studies:
–– Checklist - Hazard study 1 method –– Worked example of top-down study method
–– Applying inherent safety effectively –– Risk assessment methods and when to apply
–– What if - Hazard study 2 method –– Example of the use of risk matrices
The HAZOP study:
–– HAZOP study method, timing and team –– Recording HAZOPs and resolving actions
composition –– Team leading skills and pitfalls
–– Continuous and batch plant HAZOP - syndicate –– Awareness of safety instrumented system design
exercises –– Taking account of human factors
Control of change:
–– Examples of changes that have gone wrong –– When are full hazard studies required?
–– Good industry practice for change control –– Handling temporary modifications
–– The importance of a suitable assessment
Pre start-up safety review:
–– Hazard studies during commissioning –– Use of checklists for hazard studies 4 and 5
–– Case studies of faults during construction –– The benefits and procedure for hazard study 6
—
Hazard study leaders
Hazard studies (including HAZID and

HAZOP) are an essential element in
Duration 4 days
managing the Process Safety impact of new
projects and the ongoing operation of
existing plants. This phased approach to process safety
assessments during the life of the project
The techniques covered in this course are reduces the likelihood of discovering
directly applicable to all industry sectors significant safety or environmental
including chemicals, petrochemicals, oil & problems in the later stages of the project
gas, pharmaceuticals, fine chemicals and and ensures cost effective risk
utilities. They are well proven and highly management. The ABB hazard study
effective for identifying hazards, assessing process can be applied to continuous and
risks and developing improvement plans. batch processes, non-chemical systems and
This course will train you in the ABB PLC control systems, new projects,
techniques of the 8 stage hazard process modifications, and existing plants.
and will develop the necessary skills to lead
a team in carrying out hazard studies. What the course will cover?
The course consists of a series of training
ABB’s 8 stage hazard study stage modules that deal with the 8 hazard study
The 8 stage hazard study process covers the stages, plus sessions on related topics
full lifecycle of a project. It starts at the designed to improve the capability of
feasibility stage of a project with a study of hazard study leaders. Presentations are
the inherent safety of the project concept. interactive with some video illustrations. A
The 8 stage hazard study process then series of team exercises are used for the
mirrors the development phases of the process design stage hazard studies
project through detailed design, (including HAZID and HAZOP), to give the
construction, commissioning, and ongoing attendees a chance to put into practice
operation. At each stage there is a hazard what they have learnt during the lecture
study technique which aligns with the presentations.
needs and level of development of the
project. Who will benefit and what will they gain?
Typical attendees would be process design
The 8 stage hazard study process has been engineers, safety managers, advisors,
developed by ABB over many years engineers and works or business technical
following the invention of HAZOP studies, personnel who are likely to lead Hazard
to include HAZID studies to identify major Studies on a regular basis.
accident hazards in early process design.
H A Z A R D S TUDY LE A DER S 37
Course leader
Stephen Beedle is a safety specialist Stephen is a senior hazard study leader and
working in the areas of risk assessment, fire has been a course tutor on the ABB hazard
and explosions, fault tree analysis, process study leaders course for several years.
hazard review and COMAH safety reports.
Day one agenda*

–– Hazard Study 0 - Inherent safety, how to avoid –– Hazard Study 1 - early identification of hazards
hazards by design –– Guided exercise - development of fault trees to
–– The phased 8 stage hazard study system assess hazards
–– Tolerability of risk, what risks are acceptable –– Syndicate Exercises
Day two agenda*
–– Fires and explosions hazards –– Fault tree analysis
–– Hazard Study 2 / HAZID - establish the basis of –– Common mode and dependency
safety –– How to include human factors
–– Reliability of instrumented protective systems –– Deviation analysis based hazard study
Day three and four agenda*
–– Hazard Study 3 / HAZOP –– Leadership skills
–– Team leadership, how to lead an effective hazard –– Feedback focussed on team leadership
study –– How to apply the techniques to package units
Day five agenda*
–– Hazard Studies 4 & 5 - pre commissioning studies –– Hazard Studies of modifications
–– Hazard Study 6 - feedback from an operating –– Hazard Study 7 / Process Hazard Review - of
plant existing operations
–– Process control computers and programmable
systems

—
Human factors and
incident investigation
This training course will equip delegates
with a toolkit to enable them to carry out
Duration 1 day
incident investigations using real case
studies from the process industries.
Session 4 - Cause tree analysis
The course focuses on human error as a The technique of cause tree analysis is
cause of incidents, how human factors can explained and a number of real examples, of
be addressed during incident investigation increasing complexity, are reviewed to
and the cause tree analysis technique point out the key facets and good practice.
What the course will cover? Session 5 - Cause tree analysis exercise
Session 1 - Incident causation A syndicate exercise, based on a real
The benefits of good incident investigation incident, is used to enable delegates to
are reviewed and the domino theory of work in teams constructing a cause tree. A
incident investigation is explained as the significant amount of time is allocated to
basis for structured cause analysis. enable delegates to explore the challenges
of using the technique. Learning from
Session 2 - Human error and incident delegates’ experiences is then shared.
investigation
The SRK human error model is developed Who will benefit and what will they gain?
from practical process industry examples This course has a high practical input of
and then an exercise is used to test tools and techniques and is aimed at those
understanding and consider the difficulties required to conduct or participate in
of addressing human error using a real incident investigations, including safety
process incident. This is followed by professionals, supervisors and plant
consideration of the way that corrective managers. The course is applicable to all
actions can be developed according to the types of industrial incident.
types of errors that are encountered.
Course leader
Session 3 - The incident investigation Robert Fogg is a safety specialist and a
process chartered chemical engineer with over 20
The basic investigation process - from years of industrial experience. Rob provides
evidence collection to corrective action PSM services including: hazard studies,
development - is reviewed, including good Safety Integrity Level (SIL) determination
practice for evidence collection and witness studies, COMAH safety reports, and PSM
interviews. support. Rob’s experience includes
management of change, project planning
and coordination, hazard management and
operator training.
H U M A N FA C TO R S A N D I N C I D E N T I N V E S T I G AT I O N 39
Agenda*
Registration
Introduction
Purpose of incident investigation
Incident causation
Human error and incident investigation
Break and syndicate exercise
The incident investigation process and cause analysis
Lunch
The cause tree analysis technique
Cause tree analysis case study
Break
Syndicate exercise based on real incident
Feedback and discussion
Review
Close
—
Human factors in the workplace
Most process industry companies

acknowledge their workforce as their most
Duration 3 days
important asset. Human ‘assets’ are both
flexible and adaptable, making them unique
and valuable in a variety of situations. Who will benefit and what will they gain
The course is suitable for production
Unfortunately the very attributes that make management personnel, safety
people valuable to the production professionals and engineers in the process
organisation leaves them prone to error, industries, requiring a practical
which itself leads to the potential for safety introduction to this broad subject area.
incidents and unplanned outage. Managing
and reducing human error potential brings Delegates will return to the workplace
benefits to both safety performance and equipped with a practical questionnaire
efficiency, reducing both incidents and allowing them to assess their operating unit
outages. against current best practice, and to
identify areas of weakness or opportunities
The practical application of human factors for improvement in safety and operating
principles (sometimes known as culture.
ergonomics) is a current industry ‘hot topic’,
with increased attention being shown in the Alternatively the course can be run at your
subject by production management, safety location - price on application.
professionals, insurance inspectors /
assessors and national regulators. Course leader
Tony Atkinson is a safety specialist who
What the course will cover? specialises in human factors and process
The course runs for three days; day one is an safety. Tony has over 30 years experience in
introduction to human factors in the the process industries, both within
workplace; day two covers tangible operating companies and as a consultant.
measures to assess and improve human He is a TUV certified functional safety
performance in operations, with day three engineer and has an MSc in ergonomics
bringing in human factors in design. (human factors).
The course utilises case studies from the

process industries and from other
industries such as nuclear, aerospace, and
transport in order to illustrate key points
and learning from the widest possible
experience base. Learning will be reinforced
with group and individual exercises building
on the course materials presented.
H U M A N FA C TO R S I N T H E W O R K P L A C E 41
Agenda*
Introduction to human error
Competence
Task analysis
Alertness, fatigue and sleepiness
Risk assessment techniques
Design issues
Human factors in maintenance
Control rooms
Safety critical communications
Alarm systems
Human factors and behavioural safety
Human / machine interfaces
Procedures and instructions
Chartered Institute
of Ergonomics
& Human Factors
RECOGNISED COURSE
—
Human reliability analysis workshop
A one day interactive workshop for people

leading or participating in human reliability
Duration 1 day
analysis at high hazard sites.
What the workshop will cover? Who will benefit and what will they gain?
The workshop uses real world hazard –– Those attending the ‘ABB 3 day Human
studies, process descriptions, equipment Factors in the Workplace course’, for
photos and operating procedures. The whom it will provide an ideal opportunity
delegates take these through the steps of: to apply and consolidate the knowledge
gained on the course
–– Identification and management of safety –– Previous attendees of the above course,
critical tasks or any other similar course, wishing to
–– Hierarchical task analysis develop their knowledge
–– Human reliability analysis –– Those working in the field of human
–– Consideration of performance influencing factors and human reliability, especially in
factors the process and related industries, and
–– Key competency identification wishing to gain further insights and CPD
–– Hierarchy of control review –– The workshop assumes that all delegates
–– Demonstration of ‘ALARP’ have some basic knowledge of the topics
covered as the focus is on application of
The roles of operators and managers are practical techniques to an example
played by ABB personnel allowing delegates situation
the experience of eliciting ‘real world’
operating history and practice. Specimen Workshop facilitators
answers are discussed and critiqued by the Sarah Harrison is a specialist safety
group. The process is software driven and consultant with ABB. She has worked for
PCs and software will be provided for the ABB for 6 years, in both process engineering
duration of the workshop. and process safety. Previously, she has a
wide range of technical and operations
experience in the chemical and
petrochemical industries on high-hazard
and complex plant.
Johanna Smith is a safety specialist with

ABB. She has worked for ABB for 6 years,
both in the UK and in the US, gaining
experience in a wide range of process
safety areas, specifically safety critical task
analysis. She has a master’s degree in
chemical engineering.
H U M A N R E L I A B I L I T Y A N A LY S I S W O R K S H O P 43
Agenda*
Task inventory and prioritisation
Tea / coffee and networking
Hierarchical task analysis
Lunch
Human reliability assessment
Tea / coffee and networking
Competency
ALARP
Feedback and close

*ABB reserve the right to amend the agenda.
—
IEC 61508 / 61511 SIL determination
A practical training course in the

appreciation of SIL determination to the
Duration 2 days
technical requirements of IEC 61508 /
61511.
Industry today relies upon safety systems –– Understanding the concepts of SIL
to maintain and protect operating assets. determination and the principles of IEC
Businesses seek to maintain operating 61508 / 61511
effectiveness and reduce spurious trips –– Explaining the key terms and concepts
whilst achieving a safety target appropriate which underpin a systematic
to the circumstances. Fundamental to this consideration process for safety and
process is the determination and protective systems in respect to SIL
implementation of the safety requirements –– Understanding the importance of SIL
for the safety system. determination
–– Determine where present practice is in
From the IEC 61508 / 61511 standards, the line with the requirements of these
Safety Integrity Level (SIL) is fundamental in standards and identify where
ensuring a safety related system improvements are necessary
satisfactorily performs the required safety –– Implementing the SIL determination
functions under all stated conditions within methodology
a defined time period.
Who will benefit and what will they gain?
It is an assessment of the risk reduction The course will be of benefit to all managers
required to give a tolerable level of risk. and engineers with a responsibility for the
Inappropriate SIL determination can affect management and technical requirements of
the safety integrity of the asset protection Safety, Health and Environmental protective
envelope and may in some cases place the programmes.
asset integrity under threat. In addition to
this, unnecessary spend in capital and Course leader
operational budgets can be incurred. In Gaynor Woodford-Phillips is a safety
contrast, properly defined SILs allow for specialist for ABB and specialises in
significant cost improvements to be technical process safety which includes
achieved in both Greenfield and Brownfield carrying out target SIL assessments,
operating environments. quantified risk assessments (QRA) and
consequence modelling. Gaynor is a Fellow
Asset operational effectiveness is ensured of the Institute of Chemical Engineers with
by periodic testing of safety instrumented over 25 years’ experience in project design,
functions to maintain SIL performance and operations support and line management in
optimise the cost of ownership. the petrochemical and chemical industries.
I E C 6 1 5 0 8 / 6 1 5 1 1 S I L D E T E R M I N AT I O N 45
Day one agenda*

Introduction
Overview of IEC 61508 / 61511
Key terms and concepts
Risk and criteria
Hazard identification
Risk graph and other tools
Summary and conclusions
Close
Day two agenda*
Review of day 1
Introduction to demand trees and fault trees
Equipment failure and data
Human error
Dependency
Comparison of SIL determination tools
The CASS scheme and future issues
Review and feedback
Close

—
Layer of Protection Analysis (LOPA)
A practical one day training course to

provide an awareness and basic
Duration 1 day
understanding of LOPA.
Regulations today ask industry to manage Who will benefit and what will they gain?
risk by assessing the risk and taking This course will be of benefit to managers
appropriate action. and engineers who need to use LOPA as a
method of risk assessment.
LOPA is a method of risk assessment which
is used to carry out SIL determination to On completion of the course, you should be
comply with the IEC 61508 / 61511 able to:
functional safety standards, but is
increasingly used in early in design to –– Carry out a risk assessment using LOPA
assess whether further risk reduction is and appreciate the potential pitfalls
required. –– Understand its application in SIL
determination
LOPA is a tool that can be calibrated at the
time of use to allow assessment of the risk Course leader
reduction required to give a tolerable level Gaynor Woodford-Phillips is a safety
of risk. Inappropriate use and application specialist for ABB and specialises in
of LOPA can adversely affect the integrity of technical process safety which includes
layers of protection specified. Either carrying out target SIL assessments,
resulting in insufficient risk reduction or quantified risk assessments (QRA) and
over specification leading to unnecessary consequence modelling. Gaynor is a Fellow
spend in capital and operational budgets. of the Institute of Chemical Engineers with
over 25 years’ experience in project design,
What the course will cover? operations support and line management in
–– Basic risk assessment concepts and the petrochemical and chemical industries.
criteria, risk aversion, tolerability
including an exercise
–– Hazard identification, assessing
frequency and consequence
–– Identifying initiating causes and
independent layers of protection (IPLs)
–– LOPA use with several practical exercise
examples
–– The impact of humans in the equation
–– Selection and application of data within a
LOPA
–– Illustration of importance of independent
layers or protection
L AY E R O F P R OT E C T I O N A N A LY S I S ( LO PA ) 47
Agenda*
Introduction and background to functional safety
Risk and criteria
Hazard identification, initiating causes and IPLs
Concepts of LOPA, protection layers and conditional modifiers
Failure data and its use and application
Human failure
Dependency
Close
—
Management of Change (MoC)
A practical one day training course for

personnel who are responsible for and/or
Duration 1 day
who are involved in the topic of MoC at
Major Accident Hazard (MAH) sites.
What will the course cover?
All COMAH and Offshore Safety Case (OSC) This training course will explain the
regulated establishments are required to principles and essential features of a MoC
have a Process Safety Management (PSM) system and will discuss the practical
system, and within such a system, the topic application of such systems to changes to
of MoC must be addressed. MoC is one of Process Safety Information (PSI) and
the most important elements of a PSM organisational change. The course includes
system as it helps to ensure that safety is incident case studies where MoC
maintained on a day to day basis. Industry contributed to a major incident.
continues to suffer from loss of
containment events associated with poor A workshop is included to help delegates
MoC, so what are the essential features of a develop a plan for improving their existing
good MoC system and how does the MoC MoC system.
system link with other elements of process
safety? Who will benefit and what will they gain?
This course will be of benefit to personnel
ABB’s experience is that there is no who want to gain an understanding of
commonly adopted industry standard industry good and best practice
covering the topic of MoC and as such approaches to the topic of MoC. This is both
companies have developed bespoke in relation to equipment / process and
systems over many years. Has the system material changes and organisational
changed so much that the focus on the changes.
essential features been lost, thereby
increasing the risk of a MAH? Are users of This course will be of benefit to personnel
the MoC system fully aware of what is key to who have responsibilities under the COMAH
effectively manage change? regulations for the topic of MoC. The course
will assist delegates to:
–– Identify and correct deficiencies in their

MoC system
–– Determine ways to continuously improve
MoC effectiveness
Having a rigorous and robust MoC system

can help companies avoid major incidents
and significant business interruption.
MANAGEMENT OF CHANGE (MOC) 49
Course leader
Graeme Laughland is a safety specialist for In addition to consultancy assignments he
ABB and specialises in hazard identification tutors on a range of process safety courses
and risk assessment and PSM auditing. and has presented papers at a number of
Graeme is a chemical engineer with 30 international conferences.
years’ industrial experience gained in
design, operations and process safety
consultancy.
Course agenda*
Introductions and objectives of the day
MoC and the Flixborough disaster
MoC - technology / equipment
- Principles and essential features - Incident case studies
- Regulatory requirements - MoC workshop
- Key elements of site procedures - Links to Process Safety Information (PSI)
- What is a change? - Best practice approaches to MoC
PSI Workshop
- Video of MoC related incident - PHA tools and techniques
- Links to Process Hazards Analysis (PHA)
Pre-start-up safety reviews
- Principle and essential features - PSSR workshop
- Example checklists
MoC – personnel / organisation
- Principles and essential features - Incident case studies
- Regulatory requirements - Best practice approaches to MoC
- Key elements of site procedures
Workshop - What next?
—
Pressure relief
Are you equipped to deal with the

challenges presented by pressure relief?
Duration 3 days
There is no doubt that engineers are faced

with the ever increasing challenges that Course leader
pressure relief is imposing on our industry Chris Flower is a chemical engineering
today. Without the correct design methods specialist with over 15 years of process
and tools, overcoming these challenges engineering experience. Throughout his
would be virtually impossible. career Chris has been involved in pressure
relief be it, designing new systems,
ABB has designed a course specifically to reviewing existing systems or validating
enhance the skills that you need for sound systems designed by others across the
pressure relief design. With ABB’s extensive whole range of process industry sectors.
experience of pressure relief system design Chris has lead the pressure relief course for
and operation, providing a practical more than 7 years training over 100
perspective based on real life experience delegates a year.
comes naturally.
What will the course cover?

Days 1 and 2 of the course provide a
practical approach to all of the key steps
needed to design and maintain relief
systems. The 3rd day covers some more
complex and advanced topics.

The course is aimed at everyone involved in
the design and operation of relief systems.
Following the course you will be able to:
–– Improve your company’s overall business

safety and environmental performance
–– Get pressure relief design right first time
and avoid costly mistakes
–– Discover the potential cost effective
alternatives to pressure relief
–– Master a structured approach to pressure
relief
PRESSURE RELIEF 51
Day one agenda*

Background to pressure relief
–– What is pressure relief and why use it? –– Design team and responsibilities
–– Approach to pressure relief design –– Inherent safety in pressure relief
–– Pressure relief and the design process –– Alternatives to pressure relief
Identification of relief events
–– Identification of events leading to excessive pressure and vacuum
Calculation of the required relief rate
–– External fire –– Pumps and compressors
–– Flow from high pressure source –– Ambient heat transfer
–– Heat and energy input from associated –– Liquid expansion in pipes
equipment
Discharge and disposal
–– Discharge and disposal of vented material
Day two agenda*
Relief device hardware
–– Anatomy of a safety valve –– Devices for special applications
–– Bursting disc hardware –– Selection and types of relief devices
Relief system sizing
–– Safety valve sizing –– Computer software and pressure relief
–– Design criteria for relief systems
Installation, inspection and maintenance
–– Relief system documentation –– Relief systems inspection, maintenance and
–– Installation of pressure relief devices operation
Pressure relief codes and legislation
–– Pressure relief codes and legislation
Day three agenda*
Chemical reaction hazards
–– Developing a basis of safety for chemical reaction hazards
Blowdown and flares
–– Blowdown and flares
Two phase flow
–– Two phase flow design principles
–– Two phase flow and DIERS method
Low pressure tanks
–– Venting of low pressure tanks
–– Low pressure tank relief devices

—
Pressure relief
The practitioners course
Pressure relief is an important layer of
protection for process plant and
Duration 3 days
equipment.
Like many technical areas there are grey –– Device sizing including:
areas within the standards and pitfalls to • Supercritical relief
catch out the unwary. This course has been • Direct integral sizing methods
designed as a follow on to the ABB pressure • Liquid none certified relief valves
relief - a proven approach course. It builds –– Pressure drop calculations
upon the themes discussed and expands • Beyond 3%
these into more complex areas of the –– Low pressure storage tanks including
subject and into areas which require • Liquid overflows
engineering judgement or as the standards • Inbreathing with condensation
put it “might not be appropriate”. The –– Discharge and disposal including
Practitioners course is designed such that • Header design
engineers have time to develop their • Venting / flaring scenarios
engineering skills doing practical pressure • KO drum sizing
problems. As this is a practitioners course it • Vibration
is recommended that delegates have been –– Case study
on the ABB pressure relief - a proven
approach course or have experience with Who will benefit and what will they gain?
pressure relief through their work. This course is aimed at engineers who wish
to develop their skills and understanding of
The course will use ABB PEL software pressure relief through guided practical
during some of the tasks. Delegates will be work.
provided with the software and licence
before the course. They can bring their own Course leader
laptop, but if this is not practicable then Chris Flower is a chemical engineering
ABB can provide a training laptop. specialist with over 15 years of process
engineering experience. Throughout his
What will course will cover? career Chris has been involved in pressure
The course will cover the following topics: relief be it, designing new systems,
reviewing existing systems or validating
–– Pressure relief philosophies systems designed by others across the
–– Pressure relief scenarios whole range of process industry sectors.
–– Calculation of relief rates including: Chris has lead the pressure relief course for
• Determination of alternative relief more than 7 years training over 100
routes delegates a year.
• Multicomponent fire
• Distillation columns
PRESSURE RELIEF - THE PR AC TITIONERS COURSE 53
Day one agenda*

Background to pressure relief
–– What is pressure relief and why use it? –– Design team and responsibilities
–– Approach to pressure relief design –– Inherent safety in pressure relief
–– Pressure relief and the design process –– Alternatives to pressure relief
Identification of relief events
–– Identification of events leading to excessive pressure and vacuum
Calculation of the required relief rate
–– External fire –– Pumps and compressors
–– Flow from high pressure source –– Ambient heat transfer
–– Heat and energy input from associated –– Liquid expansion in pipes
equipment
Discharge and disposal
–– Discharge and disposal of vented material
Day two agenda*
Relief device hardware
–– Anatomy of a safety valve –– Devices for special applications
–– Bursting disc hardware –– Selection and types of relief devices
Relief system sizing
–– Safety valve sizing –– Computer software and pressure relief
–– Design criteria for relief systems
Installation, inspection and maintenance
–– Relief system documentation –– Relief systems inspection, maintenance and
–– Installation of pressure relief devices operation
Pressure relief codes and legislation
–– Pressure relief codes and legislation
Day three agenda*
Chemical reaction hazards
–– Developing a basis of safety for chemical reaction hazards
Blowdown and flares
–– Blowdown and flares
Two phase flow
–– Two phase flow design principles –– Two phase flow and DIERS method
Low pressure tanks
–– Venting of low pressure tanks –– Low pressure tank relief devices
Please note that this course will not be available till late 2019.
—
Process Safety Management (PSM)
best practice
Process safety has hit the headlines in
recent years following the major explosions
Duration 5 days
and fires at BP’s Texas City refinery and the
Buncefield storage depot in the UK.
This training course is based on the PSM
The Baker panel review in the USA and the framework provided by OSHA in the USA
Health and Safety Executive’s ‘Leading from and by the HSE in the UK. It also includes
the top - avoiding major accidents’ the practical experience of ABB process
programme in the UK has amplified the safety consultants in the design and
importance of effective Process Safety operation of high hazard process plants.
Management (PSM). An essential part of
effective PSM is an integrated and What the course will cover?
comprehensive PSM system. The PSM The course consists of presentations,
system needs to include both technical and interactive case studies and practical
organisational elements as specified in the exercises. It combines an understanding of
OSHA CFR 1910 for PSM, and the UK HSE’s the theoretical requirements with practical
HSG 65 successful Health and Safety implementation.
management. The latter is used as the
framework for demonstrating that UK Who will benefit and what will they gain?
COMAH sites comply with the requirements This course is aimed at operations
of the Seveso III directive. managers, senior process engineers and
safety specialists within an organisation
Consequences responsible for leading process safety,
Major H&S Process safety monitoring the performance of PSM
consequences arrangements and implementing
improvements to achieve high levels of
Very serious Occupational safety
internal
process safety performance. The course will
incident assist delegates to:
Slips, Trips –– Understand the key elements of a PSM

& Falls
Frequency system
–– Understand of relevant good practice
The diagram above shows how process within each element
safety generally deals with high severity –– Identify ways of improving your
and low likelihood major accidents, whereas company’s PSM system
personal or occupational safety deals with –– Network with other process safety
more routine ‘slips, trips and falls’. Both specialists
aspects of safety are equally important but –– Discuss specific issues with ABB’s
process safety has not always received the specialist consultants
attention it deserves and requires a –– Receive ABB’s detailed course manual
different approach to be adopted. with key references
PSM BEST PR AC TICE 55
Course leader
Graeme Laughland is a safety specialist for In addition to consultancy assignments he
ABB and specialises in hazard identification tutors on a range of process safety courses
and risk assessment and PSM auditing. and has presented papers at a number of
Graeme is a chemical engineer with 30 international conferences.
years’ industrial experience gained in
design, operations and process safety
consultancy.
Agenda*
Day 1 Introduction to PSM Achieving effective PSM
Management and leadership PSPIs
Day 2 Process safety information Process Hazard Analysis / Hazard studies
–– Chemical hazard information –– Techniques
–– Process technology information –– Inherent safety
–– Equipment design information –– Re-validation
Day 3 Operating procedures Safe work practices
Training and competence Contractors
Day 4 Mechanical integrity Pre-start-up Safety Reviews
Management of change Emergency planning and response
Day 5 Incident investigation Course review
Auditing
—
SIL awareness for control /
electrical technicians
Are your control / electrical engineering
teams aware of the requirements of
Duration 1/2 day
IEC 61508 / 61511 compliance for the trips
and alarms installed within your asset?
This short course is designed to give you an
With the advent of the IEC 61508 / 61511 appreciation of the following:
standards there are best practice
requirements for the specification, –– A brief introduction to the IEC 61508 /
installation, inspection, maintenance and 61511 standards and the guidance for
repair of Safety Instrumented Systems (SIS) operating, maintaining and managing SIS
installed within the workplace. ABB will help –– An introduction to risk and the concept of
you to achieve and maintain compliance for Safety Integrity Level (SIL)
your assets. Providing a practical –– An overview of designing a Safety
perspective based on real life experience Instrumented Function (SIF)
comes naturally. –– The importance of testing and
maintaining SIF
What the course will cover? –– The need for documentation and records
The course will provide you with a clear to support the operational basis of safety
understanding of the best practice
requirements for SIS operating as part of Course leader
your plant’s layers of protection. Paul Lucas is a principal safety consultant at
ABB with over 35 years’ experience of real-
Who will benefit and what will they gain? time computing and instrumented safety in
The course has been designed to be of the process chemical, oil & gas and
benefit to control / electrical technicians pharmaceutical sectors. He designs and
and supervisory staff. It will also provide delivers ABB’s training courses and
other engineering disciplines with an seminars on the practical implications for
overview of the requirements for managing end users, system integrators and
SIS. instrument technicians in the use of the
IEC61511 functional safety standard, on
As part of your overall basis of safety managing Functional Safety and detailed
management requirements, an end user design of safety instrumented functions. In
operator will be required to provide the recent years, Paul has completed a Master’s
facility control / electrical technicians with degree in Ergonomics and Human Factors
awareness training in the requirements of to gain theoretic background in support of
SIS maintenance. many years operational experience in the
assessment and analysis of Human Factors
in Safety Critical tasks, including Task
analysis and Human Error Analysis (HEA).
SIL AWARENESS FOR CONTROL / ELEC TRIC AL TECHNICIANS 57
Agenda*
Registration, coffee and bacon rolls
Introduction
Why do we need Safety Instrumented Systems (SIS)?
Functional safety standards - IEC 61508 & IEC 61511
Risk and risk reduction
Designing a safety instrumented function
Coffee
The importance of testing and maintaining safety instrumented functions
Recording, reviewing and improving
Quiz (Clarification of learning)
Questions
Close
58
—
Asset integrity
59
—
Design and operation of piping
systems
This 2 day course explains why it is
necessary to pay attention to piping
Duration 2 days
systems at all stages throughout their life
to prevent loss of containment and maintain
a licence to operate. On completion you should be able to:
What the course will cover? –– Manage the safe operation, maintenance
The main topics relating to design and safe and commissioning of piping systems
operation of piping systems which include: –– Improve business productivity by reduced
maintenance and capital costs
–– Code compliance –– Recognise the need for, and the
–– Layout importance of, design codes and
–– Routing registration of critical piping systems
–– Flexibility analysis –– Have an awareness of the technical
–– Supporting aspects of piping that must be considered
–– Testing when designing, constructing, modifying
–– Commissioning or maintaining piping systems,
highlighting the need to control
Topics are covered by discussion, case modifications
studies of real incidents and syndicate –– Identify the modes of failure of piping
exercises. It is expected that participants systems due to inadequate design,
of this course will have gained some flexibility, supporting or routing
knowledge of the subject, either by
experience or by attendance on the Course leader
appropriate courses. Graham Harvey is an asset integrity
specialist responsible for delivery of
Who will benefit and what will they gain? integrity management studies and
This course will identify the principles and strategies, including asset life extension
methods of piping design together with the studies at on and off-shore oil and gas
considerations to be taken into account for facilities, chemical and pharmaceutical
layout and routing, testing, commissioning plants. This includes conducting due
and safe operation of piping systems. You diligence studies on high hazard processes,
will gain an increased understanding of the development of integrity management
causes of piping failures and how to resolve procedures and audit protocols. Graham
the problems that can occur. has 37 years of operational experience
gained in oil and gas, petrochemicals &
The course is beneficial to anyone who is plastics, and food processing industries,
involved in design, construction, inspection, many of which were high hazard top-tier
operation or maintenance who needs a COMAH facilities.
design appreciation or to be aware of safer
piping practices.
D E S I G N A N D O P E R AT I O N O F P I P I N G S Y S T E M S 61
Day one agenda*

Introduction
Overview of design codes
Information required for design
Pressure design
Thermal design
Expansion joints - bellows
Layout and routing
Pipe supporting
Close
Day two agenda*
Review of day one
Layout and routing exercise
Special considerations (small-bore piping, dead legs, injection points)
Piping in-service inspection
NDT and pressure testing
Commissioning
Operation and maintenance
Dynamics
Review and feedback
Close
IChemE members receive discount until 31 st December 2018.

—
Essentials of pressure systems
This 2 day course aims to provide the basic

understanding of the essential elements of
Duration 2 days
pressure systems, some of the problems
encountered and how to avoid them.
The course covers the typical causes of This course is aimed at participants of all
failure of pressure equipment and provides backgrounds who require an introduction to
an overview of the UK legislative framework or refresher of the essential elements of
relating to pressure systems. pressure systems. The course would be
particularly beneficial to engineers and
What will the course cover? managers in design, construction,
An introduction to the main topics relating operations and maintenance seeking an
to Pressure Systems, which include: appreciation of pressure systems.
–– Legislation On completion you should have:

–– Pressure systems’ management
–– Vessels and low pressure storage tanks –– An understanding of the statutory
–– Piping components requirements and industry good practice
–– Valves and steam trapping for safe and reliable design and operation
–– Supports of pressurised equipment
–– Quality control –– An awareness of the problems that can
–– Pressure testing occur with pressure systems and how to
–– Pressure relief prevent them
–– Deterioration mechanisms –– An understanding of the typical causes of
failure of pressure equipment
Topics are covered by discussion, case
studies of real incidents and syndicate Course leader
exercises. An emphasis is on practical Graham Harvey is an asset integrity
issues relating to pressure systems which specialist responsible for delivery of
improves retention and interest by integrity management studies and
delegates. strategies, including asset life extension
studies at on and off-shore oil and gas
facilities, chemical and pharmaceutical
plants. This includes conducting due
diligence studies on high hazard processes,
development of integrity management
procedures and audit protocols. Graham
has 37 years of operational experience
gained in oil and gas, petrochemicals &
plastics, and food processing industries,
many of which were high hazard top-tier
COMAH facilities.
ESSENTIALS OF PRESSURE SYSTEMS 63
Day one agenda*

Introduction
Pressure systems overview
Pressure systems management including legislation
Pipes and components
Quality control and testing
Pipe joints
Vessels and heat exchangers
Low pressure storage tanks
Deterioration mechanisms
Close
Day two agenda*
Review of day one
Valves
Stream trapping
Pipe protection
Pressure relief
Pipe supports
Review and feedback
Close

—
Mechanical integrity
Lessons from process industry incidents
According to incident data, failure of
pressure equipment is the greatest
Duration 2 days
contributor to major losses of containment
in the process industries.
By better understanding how plant The course is aimed at participants of all
equipment can fail, all personnel in the backgrounds who require an understanding
process industries can improve equipment of the threats to the integrity of equipment.
integrity. Whether they are involved in the This will enable them to make better
design or operational phases, managers, contributions to risk management
engineers and operators need to be aware processes throughout the asset life cycle,
of the risks of loss of containment, poor including hazard studies, management of
reliability and inadequate plant change, and operational and maintenance
performance. procedures. The course will also benefit
anyone who is involved in the operation and
What will the course cover? integrity management of ageing plant.
This two-day course uses the findings from
process industry incidents to illustrate how On completion you should be able to:
potential threats to asset integrity can arise
throughout the asset life cycle. The course –– Appreciate the basic design requirements
will cover: for pressure equipment
–– Understand the main forms of
–– Overview of design standards deterioration and best ways to manage
–– How material properties can affect them
selection of materials of construction –– Understand the key elements of an
–– Equipment design limitations integrity management system
–– Equipment failure modes –– Identify sources of good practice
–– Forms of deterioration guidance for mechanical integrity
–– Inspection options and their limitations –– Improve management of change
–– The impact of modifications to –– Identify the key issues associated with
equipment ageing plant
The course will focus on preventing loss of

containment from pressure equipment
including pressure vessels, piping, and
storage tanks.

MECHANIC AL INTEGRIT Y - LESSONS FROM PROCESS INDUSTRY INCIDENTS 65
Course leader
Kev Senior is the Machines Functional Kev is a Chartered Engineer and Fellow of
Leader and Design Verification Engineer for the IMechE in addition to his being a
rotating equipment. He specialises in root Chartered Manager and a Fellow of the CMI.
cause analysis, fault-finding, asset health During the majority of his 30+ years
checks, life extension studies, design professional engineering career he has
verification and recommending reliability & been principally responsible for managing
maintenance improvements. the technical and logistic support of gas
turbines.
Day one agenda*

Introduction
Case study 1 - design
Overview of material properties and material selection criteria - metal and non-metallics
Case study 2 - construction and commissioning
Forms of deterioration based on API 571 & API 581
Case study 3 - mechanical deterioration
Case study 4 - operation
Close
Day two agenda*
Coffee / review of day 1
Case study 5 - maintenance
Case study 6 - inspection
Sources of good practice in integrity management
Case study 7 - Management of Change (MoC)
Organisational implications - organising for integrity
Case study 8 - asset life cycle
Review and course feedback
Close

—
Mechanical legislation awareness
Two modules covering PSSR / PED and

PUWER. Keeping track of legislation that
Duration 1 day
impacts on engineering activities.
Many companies are sinking under wave PSSR / PED

after wave of legislation and compliance The session will cover:
requirements. Whilst larger organisations
have people who are specifically employed –– Pressure Systems Safety Regulations
to keep track and help their company (PSSR)
comply, many companies cannot afford this –– The pressure equipment regulations -
expensive resource or solution. scope of regulations
–– Purchase of equipment
For these companies it is a major challenge –– Registration of equipment
to keep abreast and comply with the –– Inspection
legislation without running foul of –– Schemes of examination
Regulators, whilst at the same time keeping –– Examination and deferments
spending in proportion. Many are therefore –– Responsibilities of user
looking for cost effective solutions.
PUWER
ABB has a number of people who on a daily Provision and Use of Work Equipment
basis are emerged in understanding, Regulations (PUWER). There are few specific
interpreting, and applying UK legislation. It legal requirements relating to mechanical
is routinely engaged by organisations, large engineering practices. However, the
and small, to help with their understanding requirements of the health and safety at
and compliance issues. Getting matters into work act, the machinery directive and the
perspective is a first important step. PUWER regulations mean that the hazards
associated with equipment must be
To that end ABB has pooled its extensive identified and systems such as training,
knowledge and pulled together a one day supervision, information and instructions
awareness course, to provide an shall be used to control the hazards. The
understanding of the various aspects of session will consider:
legislation. Working through the legislation
can be daunting but ABB follows a simple –– Suitability
hierarchy which allows the important –– Inspections
messages to be understood and applied. –– Maintenance policy and practices
–– Training
–– Information
–– Compliance with EU directives
–– Responsibility of user
M E C H A N I C A L L E G I S L AT I O N A W A R E N E S S 67
Course leader
Kev Senior is the Machines Functional Kev is a Chartered Engineer and Fellow of
Leader and Design Verification Engineer for the IMechE in addition to his being a
rotating equipment. He specialises in root Chartered Manager and a Fellow of the CMI.
cause analysis, fault-finding, asset health During the majority of his 30+ years
checks, life extension studies, design professional engineering career he has
verification and recommending reliability & been principally responsible for managing
maintenance improvements. the technical and logistic support of gas
turbines.
Course agenda*
Introduction
Presentation (1st module)
Coffee and tea
Presentation (1st module)
Lunch
Presentation (2nd module)
Coffee and tea
Presentation (2nd module)
Close
—
Risk Based Inspection (RBI) and
Non-Intrusive Inspection (NII)
A practical two day training course to give
an understanding of the RBI process and
Duration 2 days
how to implement it.
Asset integrity is key to ensuring operations The journey through this risk process is
are safe, profitable and productive. diversely knowledge based. The rigour
Maintaining integrity whilst minimising applied often reveals risks that have not
downtime leads to a difficult balance. been considered previously.
Inspection of assets provides vital
information on the condition of the asset The challenge is to use this understanding
but can include intrusive examinations of deterioration mechanisms, failure modes
involving expensive preparation of and associated risks to focus attention and
equipment and down time but giving little prioritise on critical or ‘real risks’. The
information on the remnant life of the implementation of remedial measures, in
equipment. Prescriptive practises do not these identified cases, can yield significant
take account of the risk and consequence of returns in terms of risk improvements. The
failure of specific equipment. They neither level of detail and precision explored and
focus inspection on the areas of greatest the approach can range from general to
concern nor take into account the complex and can be qualitative or
knowledge of the actual operating quantitative. The approach is governed by
conditions. risks associated with the items under study.
Risk Based Inspection (RBI) offers What will the course cover?
significant benefits over conventional –– The steps involved in a qualitative (team
inspection. As well as improved risk based) RBI study, meeting the
management, typical benefits include more requirements of API 580.
uptime and reduced costs. In the UK the –– The methodology within each step of an
Pressure System Safety Regulations 2000 RBI
(PSSR) have increased the opportunity to –– How individuals can contribute to RBIs
move from prescriptive intervals and most effectively
schemes to a RBI approach. –– The information and commitment
required
The RBI approach ensures that the optimum –– The benefits of RBI
interval and scheme of examination is
implemented, concentrating on specific
deterioration mechanisms and focusing on
the areas of greatest concern. RBI allows
operating conditions and the results from
previous examinations to be used to
optimise the inspection undertaken.
RISK B A SED INSPEC TION (RBI) 69
Who will benefit and what will they gain? Course leader
This course will appeal to asset engineers Paul Jackson is an inspection specialist and
and operators wishing to understand the has over 30 years experience of the design
RBI process, the commitment required and and inspection of pressure equipment. He is
the resultant benefit. a Fellow of the Institution of Mechanical
Engineers and Chairman of its Pressure
On completion you should be able to: Systems Group Committee.
–– Understand the RBI process

–– Understand how to establish a RBI
programme within your business
–– Understand some of the key technical
issues involved in RBI studies
–– Understand the benefits of RBI
Day one agenda*

RBI overview and benefits
Syndicate task data gathering
An overview of deterioration mechanisms
Non-Destructive Testing (NDT) methods and their limitations
Review
Close
Day two agenda*
NDT quiz
Risk and risk ranking
Non Invasive Inspection (NII) - is it appropriate
Complete syndicate task on RBI of air receiver
Implementing RBI
Workshop discussion on delegate issues, demo of RBI database
Summary
Close
70
—
Maintenance
and reliability
71
—
Failure Modes & Effects and
Criticality Analysis (FMECA)
Today UK industry must be as efficient as
possible to compete in the global market
Duration 1 day
place. A key driver for this is the reliability of
the plant assets.
–– Produce generic FMEA data to apply
What will the course cover? across an equipment group e.g. pumps
The criticality analysis methodology and its –– Apply the results of both processes to the
application in prioritising equipment and generation of effective equipment
focusing reliability work. maintenance policies
Failure Modes Effects and Criticality Course leaders

Analysis (FMECA) as a method for analysing, Martin Brown is a consultant and
prioritising and avoiding potential experienced practitioner involved in
equipment failures by developing effective improving maintenance, reliability and
maintenance policies. integrity management for a wide range of
companies across the chemical, oil & gas,
The practical application of these tools to power and pharmaceutical industries.
real-life examples.
Laurence Plant is a consultant with a
Who will benefit and what will they gain? maintenance and engineering background
All plant personnel involved in improving in pharmaceuticals, chemicals FMCG and
equipment reliability and plant uptime - plastics. Laurence has been involved in a
particularly engineers, supervisors, wide range of reliability improvement
technicians and plant operators. projects.
On completion delegates will be able to:
–– Play an active part in an equipment

criticality analysis
–– Select the appropriate criteria to apply
–– Evaluate and use the results of the
analysis
–– Understand the FMECA process and how
it reveals and prioritises potential failure
modes and the effects of those failures
–– Define equipment functions and
functional failures
–– Appreciate FMEA and when to use it as
distinct from FMECA
FA I L U R E M O D E S & E F F E C T S A N D C R I T I C A L I T Y A N A LY S I S ( F M E C A ) 73
Agenda*
Criticality analysis:
–– Basic principles
–– Criteria selection
–– Rating systems
–– Using the results
–– Risk prioritisation
FMEA / FMECA:
–– Basic principles
–– Structure and application
Lunch
Functions:
–– Functional analysis
–– Function tree exercise
Failure modes:
–– Potential modes of failure
–– Potential causes and effects
–– Failure mode criticality in FMECA
–– Failure modes exercise
FMECA output
–– Using the results to develop effective maintenance policies
Close
—
Introduction to reliability workshop
Today, UK industry needs to be as safe and

efficient as possible in order to compete in
Duration 1 day
the global market place. A key factor in
ensuring these requirements is the
reliability of the plant assets. The workshop will consist of a number of
practical interactive sessions to cover the
Set against a background of ageing plant, following techniques and topics:
tighter legislation, the continuous drive for
increased production at the same time as –– Criticality analysis
cost reduction, engineers are expected to The vital starting point which allows you
improve the up-time and reliability of plant to prioritise your assets to make best use
equipment. This workshop will outline a of limited resources
number of processes and methods that you –– Loss analysis and reporting
can use to identify your reliability issues Key processes for analysing and losses
and begin to tackle them. and for focusing resources on specific
problems
You will hear from ABB reliability –– Root Cause Analysis (RCA)
consultants who as well as being A technique for identifying the
acknowledged as experts in their field also fundamental cause of an issue such as an
have a background in front-line accident or an equipment failure
maintenance management. You will have –– Failure Modes and Effects Analysis (FMEA)
the opportunity to learn from them and A method for identifying potential failures
incorporate their experiences into your and developing appropriate maintenance
improvement plans. strategies to prevent them or to mitigate
their effects
What will the workshop will cover? –– Spares management
For a number of years ABB has worked with The lack of correct spares is often a
clients in the oil and gas, pharmaceutical, fundamental cause of poor reliability. This
food, chemical, paper and metals session looks at simple techniques to
industries, helping them to improve the identify required spares
reliability of their assets. This improvement –– KPIs and benchmarking
work has ranged from delivering tailored Covers key measures of maintenance and
training packages to developing full site reliability and suggests what level these
maintenance policies. would have to reach to be called ‘World
Class’
In addition to a practical introduction to a –– What is your reliability performance?
number of reliability improvement This interactive session uses another
techniques, the workshop will give you the problem solving technique called CEDAC
opportunity to share your experience and to to look at those issues faced in their
pick up examples of good practice from the workplace by the delegates themselves
tutors and the other attendees.
I N T R O D U C T I O N TO R E L I A B I L I T Y W O R K S H O P 75
Who will benefit and what will they gain? Workshop facilitators
Representatives from all businesses and Martin Brown is a consultant and
organisations involved in the reliability and experienced practitioner involved in
maintenance of assets would benefit from improving maintenance, reliability and
attending this workshop. It would be of integrity management for a wide range of
particular interest to site managers; companies across the chemical, oil & gas,
maintenance and engineering managers; power and pharmaceutical industries.
plant engineers and reliability engineers;
plant / operations managers and health, Laurence Plant is a consultant with a
safety & environmental managers. The maintenance and engineering background
workshop will provide an excellent in pharmaceuticals, chemicals FMCG and
opportunity for networking with other plastics. Laurence has been involved in a
professionals who share an interest in asset wide range of reliability improvement
reliability. projects.
Agenda*
Introduction
Reliability - the basics
Criticality analysis
Coffee and networking
Loss analysis and reporting
Root Cause Analysis (RCA)
Lunch and networking
Failure Modes & Effects Analysis (FMEA)
Coffee and networking
Spares management
Key Performance Indicators (KPIs) and benchmarking
Maintenance and reliability issues - CEDAC
Closing comments
—
Root Cause Analysis (RCA)
Today UK industry must be as efficient as

possible to compete in the global market
Duration 1 day
place. A key driver for this is the reliability of
the plant assets.
Course leaders
What will the course cover? Martin Brown is a consultant and
The use of a structured Root Cause Analysis experienced practitioner involved in
method to find the fundamental cause of a improving maintenance, reliability and
problem. integrity management for a wide range of
companies across the chemical, oil & gas,
The practical application of the technique power and pharmaceutical industries.
to real-life examples.
Laurence Plant is a consultant with a
Who will benefit and what will they gain? maintenance and engineering background
Anybody who would value a structured in pharmaceuticals, chemicals FMCG and
approach to identifying the root cause of a plastics. Laurence has been involved in a
problem. wide range of reliability improvement
projects.
Organisations who want to give their staff
tools to help solve work related problems.
On completion delegates will be able to
–– Clearly define a problem

–– Apply the “5 Whys” root cause analysis
process
–– Create a cause tree diagram to document
the RCA process
–– Eliminate potential but incorrect causes
–– Identify the primary or Root Cause of a
problem
R O OT C A U S E A N A LY S I S ( R C A ) 77
Agenda*
Introduction
Why do we want to get to the root cause?
Problem definition
How to define a problem clearly and accurately
RCA process
The ‘5 whys method
Lunch
Recording an RCA
The cause tree diagram
Finding the primary cause
How to eliminate incorrect causes
RCA group exercise
The ‘Nail bed’ problem
Close
—
Shutdown, turnaround and outage
management
Are you equipped to manage an event that
may have a significant impact on your
Duration 1 day
business’s financial performance and the
reliability and integrity of its assets?
There is no doubt that engineers are faced Anybody from the oil & gas, chemicals,
with ever increasing challenges when petrochemicals, power, pharmaceuticals
managing shutdowns, turnarounds and and other process industries who are
outages. They are highly complex events involved in or impacted by the execution of
with significant pressure to succeed against shutdowns, turnarounds and outages on
tight timescales, constrained budgets and their facilities.
resources and a need to achieve the highest
possible HSE standards. Without an It will be of particular interest to:
understanding of a structured approach to
shutdown management achieving the goals –– Current or potential future shutdown,
of a successful event would be virtually turnaround or outage managers
impossible. –– Project engineers and managers
–– Plant maintenance engineers and
ABB has designed a course specifically to reliability engineers
enhance the skills that you will need to –– Plant / operations managers
manage a successful shutdown. It is based –– Shutdown, turnaround or outage planners
upon ABB’s shutdown, turnaround and and coordinators
outage model of excellence and our
consultants’ extensive practical experience Course leaders
of shutdown management. Martin Brown is a consultant and
experienced practitioner involved in
What will the course will cover? improving maintenance, reliability and
The course will provide a practical approach integrity management for a wide range of
to managing a successful shutdown, companies across the chemical, oil & gas,
turnaround or outage. Over the two days power and pharmaceutical industries.
the main areas of shutdown, turnaround or
outage planning and execution will be Laurence Plant is a consultant with a
reviewed together with a number of maintenance and engineering background
interactive group exercises. A course dinner in pharmaceuticals, chemicals FMCG and
will be held on the first night to enable you plastics. Laurence has been involved in a
to network effectively with other course wide range of reliability improvement
participants. projects.
S H U T D O W N , T U R N A R O U N D A N D O U TA G E M A N A G E M E N T 79
Day one agenda* Day two agenda*

Registration and coffee Planning
Introduction and overview –– Phases of planning
–– Identifying critical elements of the turnaround –– Work listing
–– How these elements interact –– Work scope
Group exercise Group exercise
–– What issues have you encountered with –– Generating a cost-effective workscope
turnarounds in your organisation? –– Planning levels and norms
The model of excellence –– Planning sequences
–– The framework for turnaround excellence Group exercise
–– How this can be used –– Planning a hazardous task
–– Outline and detailed models of excellence Contractors
Turnaround safety –– Limits of outsourcing
–– Hazards –– Upside and downside of contracting
–– Safe systems of work –– Commercial awareness and contractor
–– Safety plan engagement
–– Permit to work Cost control and estimation
–– Audits –– Business plan and impact of turnaround
–– Group exercise –– Cost control and reporting
–– Turnaround safety plan –– Cost estimation models
Turnaround quality –– Where money is spent
–– The need for quality Group exercise
–– Quality assurance issues –– Costs and assumptions
–– Quality control and issues Logistics
Turnaround organisation –– Defining and handling site logistics
–– Factors affecting organisation –– Organising stores
–– Different kinds of organisation –– Marshaling bulk work
–– Competency and skills Group exercise
–– Team building –– Strategic issues
–– Group exercise Execution
–– Organisation design –– Stages of the turnaround
Close –– Meetings and routines
*ABB reserve the right to amend the course agenda. –– Controlling the event
–– Performance review
Close
80
—
Other
81
—
Construction, Design and
Management (CDM) awareness
This half day course aims to raise awareness
and give an overview of the background,
Duration 1/2 day
objectives and requirements of the CDM
Regulations with an emphasis on the
changes to the Regulations introduced in Who will benefit and what will they gain?
2015. The course provides information on the
legal duties under current legislation for
The course provides information on the individuals and organisations involved in
legal duties under current legislation for construction activities.
individuals and organisations involved in
construction activities. On completion you should have:
What will the course cover? –– Un understanding of the legislation and

–– Overview of CDM legislation, including the roles and responsibilities of the
background, when does it apply, various duty holders
objectives and history –– An understanding of the changes made in
–– Main changes introduced under CDM 2015 2015 and the reasons behind these
–– Summary of Roles & Responsibilities and changes
legal requirements of all parties –– An understanding of the requirements at
–– Summary of CDM requirements at each each stage of a project and associated
project stage documentation
Typical documentation Course leader

–– CDM requirements relating to Charles Dent is an experienced project
Maintenance works manager with over 20 years’ experience of
managing engineering projects in the
power, oil & gas and pharmaceutical
industries. Charles is a member of the
project management Institute and has
worked with CDM since its inception in 1994
C O N S T R U C T I O N , D E S I G N A N D M A N A G E M E N T (C D M ) A W A R E N E S S 83
Agenda*
Introduction
Background and history
2015 update - what has changed?
Duty holders
Documentation
Other provisions
Penalties and consequences
Summary
Close
—
Project management in the
process industries
“How much does poor project delivery cost
your business; and what would it be worth
Duration 2 days
to make a step change in performance?”
“Doing the wrong projects well is not much Who will benefit and what will they gain?
help” The training is aimed at people newly
appointed into project positions including:
Good project management needs to
address both: –– Project managers
–– Project engineers
–– How to identify and define the best –– Project participants
project to meet the business objectives
–– How to deliver that project in a safe, cost On completion you should be able to:
effective way
–– Define project objectives that align with
ABB has good experience of providing business objectives
project management training to operating –– Know the features of and see the benefits
companies in the process industry. We of a well managed project
understand the particular challenges that –– Understand how to identify and manage
are faced by companies in the chemical, oil key stakeholders
& gas and power sectors when delivering –– Understand and have practised the core
complex and potentially hazardous projects tools and techniques required as a project
in a highly regulated environment. Our participant or manager
trainers all have strong backgrounds in –– Understand the key skills required as a
projects, engineering and operations in the project participant or manager
process industry and are able to bring their
own experiences to the training courses Course leader
that we run. John Weston is an experienced project
manager and project control consultant,
What will the course will cover? with particular expertise in managing
–– A generic project process and the key multifunctional project teams and
elements of a successful project consultancy assignments in various
–– The role and skills of the project manager industry sectors.
–– Managing key interactions, stakeholders
and the project team
–– Key tools for use through the project
lifecycle - planning, scheduling, risk
management and option analysis
PROJEC T M A N AGEMENT IN THE PROCESS INDUS TRIES 85
Day one agenda*

What is a project?
Project process and key stages
Project benefits, objectives and scope
Stakeholders
Option evaluation
Day two agenda*
Planning and scheduling
Estimating
Managing uncertainty - risk and value management
Project execution and control
— —
ABB Limited ABB Limited
Daresbury Park The Deep Business Centre
Daresbury Tower Street
Warrington Hull
Cheshire HU1 4BG
WA4 4BT United Kingdom
United Kingdom Phone: +44 (0)1482 481160
Phone: +44 (0)1925 741111 E-Mail: contact@gb.abb.com
E-Mail: contact@gb.abb.com
— —
ABB Limited ABB Limited
Pavilion 9 The Shearer Building
Byland Way Earls Road
Belasis Business Park Grangemouth
Billingham Stirlingshire
Cleveland FK3 8XG
TS23 4EB United Kingdom
United Kingdom Phone: +44 (0)1324 494406
Phone: +44 (0)1642 372000 E-Mail: contact@gb.abb.com
—
ABB Limited
Hareness Road
Altens Industrial Estate
All rights reserved
Aberdeen
AB12 3LE
United Kingdom
Phone: +44 (0)1224 592123
Copyright© 2018 ABB
abb.com/consulting

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Introduction 54 Process Safety Management (PSM)

In high hazard industries, assuring the

We believe in being flexible and sensitive

years experience. For example:

Some courses are accredited / –– In-house courses delivered at client

These courses have been successfully

We understand that not all companies

We also run regular open courses

Our up-to-date course schedule is

For course enquiries, contact our

Reduced terms and conditions It may be necessary for reasons beyond

Graeme has over 33 years experience in —

Chris has over 15 years of process —

Process safety courses In-company Open

Asset integrity courses In-company Open

Design and operation of piping systems X X

Essentials of pressure systems X X

Mechanical integrity - lessons from process industry incidents X

Mechanical legislative awareness X X

Risk Based Inspection (RBI) X X

Maintenance and reliability courses In-company Open

Failure Modes & Effects and Criticality Analysis (FMECA) X X

Introduction to reliability workshop X

Root Cause Analysis (RCA) X X

Shutdown, turnaround and outages management X

Other In-company Open

Construction, Design and Management (CDM) awareness X

Project management in the process industries X

New for 2019 In-company Open

Essentials of rotating machines X X

Essentials alarm management X X

Process Industries rely upon the

What the course will cover? Course leader

Syndicate topics –– Use of minimum cut-sets to analyse

IChemE members receive discount.

Are you looking to improve your skills as a

Do you want to become a more competent

Benefits Course leader

Employers have now been living with the

Registration and coffee

Introduction and overview of legislation

Properties of flammable materials

DSEAR compliance in the chemical and pharmaceutical industries

Hierarchy of control and area classification

Area classification exercise

Overview of certified equipment

ATEX certification for fans

Retrospective certification for mechanical equipment

What is your process? Can you have

Have you identified the likelihood of a

–– Understand the requirements for Course leader

Day one agenda*

IChemE members receive discount.

–– A brief introduction to the ATEX 95 and

Registration, coffee and bacon rolls

A practical one day training course for

and recommendations and the guidance The training method

Day one agenda*

IChemE members receive discount.

A practical one day training course to

In addition to catastrophes such as the What the course will cover?

This course is aimed at providing a

Day one agenda*