Brochure Training PDF

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Te c h Training Institute
PrimaT
TRAINING FOR PROCESS SAFETY,

SECURITY AND RISK MANAGEMENT
COURSE CATALOG
Te c h Inc.
PrimaT
Specialists in Safety, Security and Risk
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1 Get The PTI Advantage!
Te c h Training Institute
PrimaT
Specialists in Safety, Security and Risk
Comprehensive Training The Best Training Available
Primatech Training Institute (PTI) provides compre- Comprehensive Training

hensive and up-to-date open-enrollment courses for More than 35 courses on process safety, security and risk
process safety and risk management professionals. management are all designed by industry experts who
are recognized leaders in process safety. Primatech
Our objective is to teach participants how to satisfy the
courses are continually updated with the latest technical
regulatory requirements mandated by OSHA and EPA,
information and regulatory clarifications.
meet other federal, state and industry process safety
and risk management standards and promote safe Expert Trainers and Advanced Training Delivery
process operations. Our instructors use the latest advances in training deliv-
ery and adult learning techniques.
Many process industry companies look to Primatech to
help interpret, develop and implement their process Convenient Locations
safety management (PSM) and risk management Open enrollment courses are available throughout the
programs (RMP) through our professional consulting year in cities in North America, Europe and Asia.
services.
Customized Training Available
Our PTI courses are the training extension of these Courses can be customized to meet your needs and
expert services. Primatech keeps the process industries delivered at your site.
informed of the latest technical approaches, industry
Examples, Exercises and Hands-On Workshops
best practices and regulatory clarifications with contin-
Examples, exercises and hands-on workshops are used to
ually updated course content. This ensures that partici-
provide practical experience and reinforce the training.
pants always receive the best, most up-to-date techni-
cal instruction possible. Course Manuals and Resources
You take away a detailed course manual, resource mate-
rials, handouts, job aids, and checklists to help you apply
what you have learned after the course.
In House Training Available Learn More
All PTI courses are available for delivery at your site or For more information about Primatech Training Institute
a nearby location. This is often more economical if you and customized in-house training, please contact a
have five or more participants. In-house courses can Primatech representative directly at (614) 841-9800 or
also be customized to include site or company specific www.primatech.com/training.
information and process examples for workshops.
See page 25 for details.
Multi-Course Discounts Consulting
Take any two courses during the same week and Primatech provides consulting services to help compa-
receive a multi-course discount off the total price. One nies with regulatory compliance and reduce the likeli-
multi-course discount per week is allowed. Please ask hood and consequences of hazardous chemical releases.
about our current multi-course discount policy. Our process safety, security and risk management consult-
ing services help companies comply with OSHA PSM and
EPA RMP regulations. Call us for complete information.
Multi-Registration Discounts Register by Fax, Phone or Email
Receive a 10% discount off the total price when three Fax: (614) 841-9805
or more employees from the same company attend the Phone: (614) 841-9800
same course(s) at the same time. Email: training@primatech.com
Copyright © 2008, Primatech, Inc., All rights reserved.
1 Te c h Training Institute | Visit www.primatech.com/training | Call (614) 841-9800 to Register

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Contents 2
Courses Page Page
PROCESS HAZARD ANALYSIS (PHA) HUMAN FACTORS AND HUMAN ERRORS

PHA for Team Leaders . . . . . . . . . . . . . . . . . . . . . . . .3 Principles of Human Factors for Process Safety . . .17
Advanced PHA for Team Leaders . . . . . . . . . . . . . . .4 Human Factors Methods for Process Safety . . . . . .18
Refresher Training for PHA Team Leaders . . . . . . . .5 Understanding and Applying Human
Factors to Control Systems . . . . . . . . . . . . . . . . . . .19
PHA for Team Members . . . . . . . . . . . . . . . . . . . . . . .5
Human Error and Reliability Analysis . . . . . . . . . . .20
S84 / IEC 61511 AND LOPA
MOC AND MECHANICAL INTEGRITY
S84 / IEC 61511 Standard on Safety Instrumented
Systems (SIS) and the Development of a Safety Management of Change (MOC)
Requirements Specification (SRS) . . . . . . . . . . . . . .6 for Process Safety . . . . . . . . . . . . . . . . . . . . . . . . . .21
Layers of Protection Analysis (LOPA) Mechanical Integrity (MI) for Process
for Process Safety Management . . . . . . . . . . . . . . . .7 Safety and Risk Management . . . . . . . . . . . . . . . . .22
Safety Integrity Level (SIL) Verification

for the S84 / IEC 61511 Standard on PROCESS AND CYBER SECURITY
Safety Instrument Systems (SIS) . . . . . . . . . . . . . . .8
Process Security Management . . . . . . . . . . . . . . . .23
Security Vulnerability Analysis (SVA) . . . . . . . . . . . .24

SOFTWARE
PHAWorks® Training . . . . . . . . . . . . . . . . . . . . . . . . . .9 Understanding and Applying Cyber Security for
Manufacturing and Computer Control Systems . . . .25
Tips and Tricks for Using PHAWorks® . . . . . . . . . . .10
Cyber Security Vulnerability Analysis (SVA) for
Using TrackerTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Manufacturing and Computer Control Systems . . . .26
PROCESS SAFETY MANAGEMENT

Designing and Implementing a PSM Program . . . .12 Other Courses, Products & Services
Auditing PSM Programs . . . . . . . . . . . . . . . . . . . . .13
IN-HOUSE TRAINING COURSES . . . . . . . . . . . . . .27
Schedule Primatech courses at or near your facility
JSA, PROCEDURE WRITING
PHAWorks®
Job Safety/Hazard Analysis — SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Assessing Workplace Hazards . . . . . . . . . . . . . . . .14
Tracker TM
Start documenting PHA studies in minutes
Principles of Procedure Writing . . . . . . . . . . . . . . . .15
AUDITWorksTM
Advanced Procedure Writing . . . . . . . . . . . . . . . . . .16 Track action items from inception to completion
Complete Safety, Health and Environmental Audits
CONSULTING SERVICES . . . . . . . . . . . . . . . . . . .30

Expert consulting services available
Visit www.primatech.com for current discount offers on training and software promotions. 2
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3 Process Hazard Analysis
Process Hazard Analysis (PHA) for Team Leaders

Course Length: 5 Days Accreditation: 3.5 CEUs
The course provides you with specific detailed guidelines for facilitating Target Audience
PHA studies, including PHA Revalidations, which you will practice in Engineers, PSM Specialists, and others
workshop sessions. Includes tactics to ensure a successful study. responsible for leading PHA studies.
Prerequisite
OSHA expects that process hazard analysis (PHA) team leaders be qualified to lead
Course Description Familiarity with P&IDs is required.
PHAs either by experience prior to the issuance of the PSM standard (which was
promulgated in 1992) or through training.
Course Contents
This course helps prepare team leaders to facilitate PHA study teams. In addition to
• Overview of PHA
receiving expert instruction on the technical and managerial procedures involved with
• PHA Regulatory Requirements
leading a PHA team, you’ll form a study team with other participants and take turns
• What-If Studies
leading the team. Workshops are overseen by an instructor who will give feedback on
• HAZOP Studies
your performance. Participants discover the tactics and success factors that help
• Preparing and Organizing PHA Studies
ensure a successful study.

• Inherent Safety Review
While Primatech’s PHA software, PHAWorks®, is used by attendees during the work-
• Subdividing the Process for Study
shop sessions of the course, the PHA for Team Leaders course is not a software
• Design Intent, Parameters
course, and instruction in the software is not included.

and Deviations
• Completing the PHA Worksheet
Upon completing this course you will receive certification of training to satisfy
• Recording PHA Studies
OSHA’s requirements for PHA team leaders.

• Meeting Regulatory Requirements
• Leadership Skills for Managing
the Team
• Management of PHA Studies
• Human Factors in PHAs
• Facility Siting in PHAs
• Treating Utilities
• Handling Multiple Modes of Operation
• PHA for Process Changes
• PHA for Procedures
• PHA for Batch Processes
“Anyone in the chemicals industry • Quality Control in PHA Studies
should take this course.” • PHA Report Preparation
• Managing the Follow-Up of
— James Sullivan, BASF
PHA Results
• Planning PHA Revalidations
• Conducting PHA Revalidations
• Documenting PHA Revalidations

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Process Hazard Analysis 4
Advanced PHA for Team Leaders

Course Length: 2 days Accreditation: 1.4 CEUs
Go beyond fundamentals to more advanced issues including the Target Audience

use of PHA to analyze in detail the hazards of batch processes, Those who have received formal PHA
procedures, control systems, and reactive chemicals. training; PHA Team Leaders and partici-
pants; PSM coordinators.
The OSHA PSM and EPA RMP regulations are performance-based. They antici-
Course Description Prerequisite
pate that performance standards will evolve and improve over time and they require
Primatech’s PHA for Team Leaders training
compliance with good engineering practices. Over the past few years, a number of
course (or equivalent). Also, attendees
approaches that go beyond the basics of classical PHA have been developed, doc-
must be able to read and understand Piping
umented and applied. Companies should consider implementing these approaches

& Instrumentation Diagrams (P&IDs).
to ensure compliance with the regulations and the proper management of risk. Course Contents
This course goes beyond the fundamentals of facilitating the performance of PHA
• PHA for Batch Processes
covered in the course PHA for Team Leaders and deals with more advanced issues
• PHA for Procedures
including the use of PHA to analyze in detail the hazards of batch processes, pro-
• S84 Standard and Layers of
cedures, control systems, and reactive chemicals, and to help meet the requirements
Protection Analysis (LOPA)
of the ANSI/ISA S84.01 standard on safety instrumented systems.

• LOPA and PHA
• Overview of Reactive Chemical Hazards
The course explains how HAZOP, What-If and other PHA methods can be used to
• Identifying Reactive Chemical Hazards
identify the potential for errors in executing operating, maintenance and other pro-
• Reactive Chemicals in PHA
cedures. The application of these methods to batch procedures and processes is also
• Failure Characteristics of
explained. PHA techniques that can be used to explicitly analyze the hazards of
Control Systems
process control systems are also described. This provides a more detailed descrip-
• PHA for Control Systems
tion of control systems hazards than is possible with classical PHA.

• Major Hazards Analysis
OSHA has announced its intent to revise the PSM standard to better address the
hazards of reactive chemicals. The Chemical Safety Board has also recommended
that both OSHA and EPA include reactive chemicals in their process safety and risk
management regulations. This course covers approaches for addressing the hazards
of reactive chemicals in PHA.
OSHA also expects companies to comply with the S84 standard and the course
explains how PHA can be used to help accomplish this objective.
Examples are provided of the application of the PHA approaches described
and attendees participate in workshop sessions to gain experience using the
approaches.
This course was developed for those who have received formal PHA training and
experienced PHA team leaders. An understanding of PHA regulatory requirements
and experience or formal training as a PHA team leader is necessary to be success-
ful in this course.
“Excellent instructor with excellent

knowledge of PHA and PSM.”
— Rich Kennedy, PSM Manager, Husky Oil - Lima Refinery
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5 Process Hazard Analysis
Refresher Training for Process Hazard Analysis (PHA) Team Leaders

Brush up on your skills as a PHA facilitator. Learn the latest regulatory and
Target Audience
technical developments in PHA. PHA facilitators who have previously been
trained as PHA team leaders.
Refresher Training for Process Hazard Analysis (PHA) Team Leaders is intended for
Course Description
PHA facilitators who were trained more than two years ago. The course covers the lat-
Prerequisite
est PHA regulatory clarifications and current best practices in conducting PHAs. It
Prior attendance at Primatech’s training
addresses the performance of both initial and revalidation PHAs. Examples, exercis-
course, PHA for Team Leaders, or equiva-
es and workshops are used to reinforce the material covered.

lent. Also, attendees must be able to read
and understand Piping & Instrumentation
Attendees receive a detailed course manual and electronic copies of regulatory stan-
Diagrams (P&IDs).
dards, resource materials, job aids and checklists.

Course Contents
Upon completing this course you will receive re-certification as a PHA Team Leader.
• Key PHA Concepts
• Regulatory Clarifications
• Getting Ready
• Preparing and Organizing
• Process Subdivision
• Completing the Worksheet
• Special Topics
• Human Factors
• Facility Siting
• Multiple Modes of Operation
• PHA Revalidation
• Overview
• Preparation
• Conducting and Documenting
Process Hazard Analysis (PHA) for Team Members

Learn how to be an effective PHA team member and understand the Target Audience
regulatory and technical requirements that govern the performance Operations, engineering, maintenance and
of PHA. other technical personnel who will serve as
members of PHA teams.
PHA for Team Members teaches attendees to be an effective contributor to PHA team
sessions. Participants gain an understanding of the regulatory and technical require-

None
ments that govern the performance of PHA. Guidelines for their participation in PHA
sessions are provided and explained.
Course Contents
• Key PHA Concepts
Attendees practice serving as a team member in the performance of a PHA led by the
• Regulatory Requirements
course instructor.
• What-If and What-If / Checklist Studies
• Key Points
Attendees receive a detailed course manual and electronic copies of regulatory stan-
• Hazard and Operability (HAZOP) Studies
dards, resource materials, job aids and checklists.

• Preparation and Organization
• Conduct of PHAs
• Revalidation of PHAs

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S84 / IEC 61511 and LOPA 6
S84 / IEC 61511 Standard on Safety Instrumented Systems (SIS)

and the Development of a Safety Requirements Specification (SRS)
Course Length: 1 Day Accreditation: 0.7 CEUs
Learn the requirements of the S84 / IEC 61511 standard, how to select Target Audience
appropriate safety integrity levels and how to manage SISs throughout Process safety personnel, instrumentation
their life cycles. engineers and others who need to apply
the S84 / IEC 61511 standard.
Safety instrumented systems (SISs) play a key role in process control to achieve safe-
Prerequisite
Course Description
ty and productivity. Their purpose is to take a process to a safe state when predeter-
Experience in process safety is helpful.
mined set points are exceeded. SISs are also called emergency shutdown systems,
safety shutdown systems, and safety interlock systems.
Course Contents
• SIS Concepts and Terms
Several standards have been enacted to address the reliability of SISs. ANSI/ISA
• Standards and Regulations
Applicable to SIS
S84.00.01-2004, Functional Safety: Safety Instrumented Systems for the Process

• S84 Requirements
Industry Sector, first issued in 1996, has now been harmonized with IEC 61511
• Process Hazard Analysis and S84
issued in 2003. In March 2000, OSHA issued a letter, reaffirmed in November 2005,
• Preparation of a Safety Requirements
stating that the S84 standard is considered “good engineering practice” for safety
Specification (SRS)
instrumented system design. This effectively makes the S84 standard part of process
safety management (PSM) since paragraph (d)(3)(ii) of the OSHA PSM standard
specifies: “The employer shall document that equipment complies with recognized
and generally accepted good engineering practices.”
S84 / IEC 61511 identifies three Safety Integrity Levels (SILs) for the process indus-
tries and specifies site performance requirements for each level. Different levels of
risk require different levels of safety system performance.
SILs are often determined using information taken from a process hazard analysis
(PHA). PHAs as currently performed often do not include all the information needed
for SIL determination. The course provides guidelines to facilitate performing PHA
for SIL determination and attendees participate in a workshop session to practice
using these guidelines.
This course describes all the requirements of the standard. However, a key require-
ment is the development of a Safety Requirements Specification (SRS). The course
explains how to prepare the SRS. Also, attendees develop an SRS in a workshop ses-
sion.
A detailed manual is provided for your use as a reference after you have completed
the course.
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7 S84/IEC 61511 and LOPA
Layers of Protection Analysis (LOPA) for Process Safety Management

Learn each step in performing LOPA and gain experience in its use. Target Audience
Process safety personnel, PHA
analysts and others who need to
Layers of Protection Analysis (LOPA) is a simplified form of risk assessment. It

Course Description apply or understand LOPA.
assists compliance with PSM and RMP regulations and with the ANSI/ISA
S84.00.01-2004 standard, Functional Safety: Safety Instrumented Systems for the
Prerequisite
Process Industry Sector.

Experience in process safety and
process hazard analysis is helpful.
LOPA is often used as an extension of process hazard analysis (PHA). PHA teams
use engineering judgement to decide if additional safeguards are needed to protect
Course Contents
against accident scenarios they identify. This subjective approach can lead to dis-
• Overview of LOPA
agreements and possibly inappropriate measures to reduce risk. A more rational and
• Process Safety Concepts
objective approach is needed, at least when considering risk remediation measures

• Use of LOPA
for high risk scenarios or those that are expensive to implement. LOPA was devel-
• Documentation and Example Application
oped for this purpose.

• Selecting Scenarios, Defining
Consequences, and Identifying
LOPA is also used to comply with the S84 standard. S84 requires the allocation of
Initiating Events and Enablers
safety functions to protection layers, the determination of required Safety

• Identifying Existing Independent
Instrumented Functions (SIFs) and the determination of their Safety Integrity

Protection Layers (IPLs)
Levels (SIL). LOPA is one method used for this purpose. The required SIL of a SIF
• Estimating Scenario Risk
is derived by taking into account the required risk reduction to be provided by that
• Making Risk Decisions
function. S84 notes that this is best accomplished as part of a process hazards and
• Worked Examples
risk analysis (i.e., a PHA) to benefit from possible synergies and the information
• Implementation Issues for LOPA
developed.
• Other Uses of LOPA
LOPA is used to evaluate scenario risk and compare it with risk tolerance criteria
to decide if existing safeguards are adequate, and if additional safeguards are need-
ed. Without risk tolerance criteria, there is a tendency to keep adding safeguards in
the belief that the more that are added the safer the process will be. This can be a
false assumption. Eventually, unnecessary safeguards will be added, increasing
complexity and resulting in new unidentified hazard scenarios. LOPA helps focus
limited resources on the most critical safeguards.
This course describes each step in performing LOPA and uses examples, exercises
and workshops to provide experience in its application. A detailed manual is pro-
vided for use as a reference after you have completed the course.
“The course is quite outstanding; it is a must for all

(of the) process and oil and gas industries.”
— Jacob Ologe, HSE Audit / Inspection Officer,
Total Elf Petroleum Nigeria Limited

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S84 / IEC 61511 and LOPA 8
Safety Integrity Level (SIL) Verification for the S84 / IEC 61511
Standard On Safety Instrumented Systems (SIS)
Learn how to perform calculations to verify SILs for Safety Instrumented Target Audience
Functions and Systems using a variety of methods. Process safety personnel, instrumentation
engineers, reliability engineers and others
who need to perform or understand SIL
ANSI/ISA S84.00.01-2004, Functional Safety: Safety Instrumented Systems for the

Course Description verification calculations.
Process Industry Sector, requires that claimed Safety Integrity Levels (SILs) be ver-
ified by calculation. Calculation modeling methods are chosen based on the cir-
Prerequisite
cumstances. Methods include simulation, reliability block diagrams, cause-conse-

A degree in engineering or another
quence analysis, fault tree analysis, and Markov models.

technical discipline is required. Familiarity
with control systems and experience in
Factors that should be included in the modeling include architecture; technology;

process safety is helpful.
field device configuration; susceptibility to common cause failures; component

Course Contents
failure rates; level of redundancy and voting; proof tests and intervals; diagnostics
• S84 Overview
including reliability, test intervals and coverage; repair times and susceptibility to
• SIS Components and Their Failures
external influences. Workshops are used to practice the methods taught.

• Reliability Concepts
• Reliability Block Diagrams
A detailed manual is provided for use as a reference after you have completed
• Cause-Consequence Analysis
the course.
• Failure Modes, Effects and
Diagnostic Analysis
• Fault Tree Analysis
• Markov Models
• Sources and Use of Failure Rate Data
• Modeling SIS Components
• SIL Verification
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9 Process Safety Software
®
PHAWorks Software Training
Course Length: 1.5 days Accreditation: 1.4 CEUs
Learn how to best use PHAWorks® software, including all of its

Target Audience
capabilities, from basic to advanced features. Individuals responsible for using
PHAWorks® to record PHA studies. These
Recording the results of PHA studies is a vital part of performing such studies.
individuals may include the PHA Team
Course Description
PHAWorks® is a Windows-based computer software application that facilitates the

Leader, PHA Scribe, PHA Coordinator, PSM
electronic recording of studies.

Manager or other people involved in com-
pleting PHA studies.
As with most Windows software, PHAWorks® is designed to allow its use right out
of the box without reading the User Guide. However, users will then only employ
Prerequisite
a fraction of the software’s capabilities. Great improvements in the speed and effi-
Knowledge of PHA techniques, particularly
ciency of performing studies are possible with an investment to understand the

HAZOP, and an understanding of processes
software’s capabilities. Attendees learn the ropes of using the software from
are necessary. Attendees should have a
Primatech instructors who are thoroughly versed in the software.

basic understanding of Windows-based
This course provides PHAWorks® users with an understanding of the full capabili-
software applications. Students should
ties of PHAWorks®, starting with the basics up through the advanced features of the
come to the course with PHAWorks®
software.
installed on a personal computer (a limited
number of computers are available for
This course will benefit those who have familiarity with PHAWorks®, or those who
rental from Primatech).
are using PHAWorks® for the first time. Course Contents

• Creating PHA Projects
• Entering Information and Data in Dialogs
and the Worksheet
• Navigating Project Files and
the Worksheet
• Commonly Used Features Including
Find/Replace, Spell Check, Formatting,
“Very good and qualified instructor. Undo/Redo
• Generating Customized Reports
Sensitive to audience needs.” • Using Quick Entry® Lists and Quick Copy®
— Mark Prude, ISP Chemicals to Speed Up Data Entry
• Adding Notes to Worksheet Entries
• Customizing the Appearance of
the Worksheet
• Use of Analysis Tools and the Library
• Creating Master Lists of Team Members
• Use of Passwords to Protect Projects
• Using Hyperlinks
• Configuring Projects
• Converting Projects from Other Formats
• Exporting Projects to Other Applications
• Copying Files from Other Projects
• Automatic Worksheet Numbering
• Use of References in the Worksheet
• Using Sage® and its Database
• Revisions to Worksheets
• Tracking Worksheet Changes
• Revalidating Studies
• Archiving Projects
• Using Protocols for PHA Revalidation
• Configuring Software Preferences

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Process Safety Software 10
Tips and Tricks for Using PHAWorks®

Learn how Primatech’s PHA facilitators use PHAWorks® to conduct Target Audience
effective and efficient PHA studies. Individuals responsible for using
PHAWorks® to record PHA studies. These
PHAWorks® is designed so that it can be easily used out-of-the-box without read-

individuals may include the PHA Team
Course Description
ing the User Guide. Indeed, many users rely on their PHA and Windows® knowl-
Leader, PHA Scribe, PHA Coordinator, PSM
edge to use the product. However, such users may miss the benefits of many fea-
Manager or other people involved in com-
tures in the software that can be used to speed up and increase the effectiveness of
pleting PHA studies.
PHA studies. This course teaches how Primatech’s own PHA facilitators use the
software with their intimate knowledge of its features and how the features were
Prerequisite
intended to be used in PHA studies.

Attendees should have a basic understand-
ing of PHA and Windows-based software
applications. Students should come to the
course with PHAWorks® installed on a
personal computer (a limited number of
computers are available for rental from
Primatech).
Course Contents
• Configuring a PHA Project
• Defining the Study Purpose, Scope
and Objectives
• Establishing and Using Library Checklists
• Recording Attendance
• Documenting and Linking to
Reference Drawings
• Fast Ways for Entering Worksheet Data
• Navigating the Worksheet
• Using Worksheet References
• Automating Worksheet Entries
Using Sage®
• Changing the Worksheet Display
• Backing Up Projects
• Customizing Reports
• Revising Worksheets
• Updating and Revalidating PHAs
• Creating Templates for Other Types
of Studies
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11 Process Safety Software
Using Tracker Software TM
Learn how to use TrackerTM to efficiently and effectively Target Audience

manage action items. Individuals responsible for tracking action
items using TrackerTM. These individuals
Tracking recommendations (action items) from Process Hazard Analyses (PHA),

may include PHA or SVA Coordinators,
Course Description
Security Vulnerability Analyses (SVA), Audits, Management of Change (MOC)

PSM Managers, Security Managers, MOC
reviews, Incident Investigations, etc. is a vital part of managing risk, safety and
Coordinators, Auditors, or others.
security at process plants. Indeed, OSHA PSM and EPA RMP regulations require a
management system be used to track and implement PHA recommendations.
Prerequisite
TrackerTM is a Windows-based computer software application for tracking action

Attendees should have a basic understand-
items. It is the most powerful and comprehensive package available.

ing of Windows-based software applica-
tions. Students should come to the course
Users will benefit from training in the use of its features to provide greater efficien-
with TrackerTM installed on a personal com-
cy and effectiveness in using the software. Attendees learn the ropes of using the
puter (a limited number of computers are
software from Primatech instructors who are thoroughly versed in the software. The
available for rental from Primatech).
course instructor provides numerous “tips and tricks” for using the software.
Course Contents
This course will benefit those who have a basic familiarity with TrackerTM, or those
• Creating Files
who are using TrackerTM for the first time.

• Users and Passwords
• Importing / Adding Items
• Address Book
• List Views
• Activity Views
• Sorting
• Filtering
“Instructor is very knowledgeable • Display Options
and teaches a valuable class.” • Form Configuration
• Adding New Fields
— Tjay Jenn, Petro Star Valdez Refinery • Group Update
• Find / Replace
• Links
• Escalate Items
• Numbering
• Spell Check
• Navigating
• Sending Requests
• Sending Responses
• Reviewing Responses
• Reminders
• Reports
• Closing Items
• Updating PHAWorks
• Scheduled Tasks
• Exporting
• Source Types
• Options
• Email

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Process Safety Management 12
Designing and Implementing a Process Safety Management (PSM) Program

Learn how to ensure that your PSM program meets the requirements
Target Audience
of OSHA and EPA in preventing catastrophic accidents for covered
Managers, process safety coordinators
processes.
and others responsible for satisfying
PSM regulatory requirements.
OSHA’s PSM Standard (29 CFR 1910.119) and EPA’s Risk Management Program
rule (40 CFR Part 68) both require the development and implementation of a pro-
None
gram to prevent catastrophic accidents for covered processes. These are perform-
ance-based regulations and are subject to ongoing interpretations and clarifications
Course Contents
from the regulatory agencies. The prevention programs are wide-ranging and cover
• Overview of Prevention
virtually every aspect of a company’s operations. Companies are often unsure on

Program Regulations
what constitutes full compliance with the regulations.

• Requirements for Compliance
• Employee Participation
This course explains how to ensure your prevention program is designed to meet
• Process Safety Information
the requirements of these performance-based regulations and implemented through

• Process Hazard Analysis
an effective management system.

• Operating Procedures
• Training
Examples of PSM elements are provided and illustrated with exercises and work-
• Contractors
shops.
• Pre-Startup Safety Review
• Mechanical Integrity
• Hot Work Permit
• Management of Change
• Incident Investigation
“Excellent compilation on all aspects of PSM. • Emergency Planning and Response
Information provided can be used to improve • Compliance Audits
• Trade Secrets
PSM at Petrojam; ideas as to how I can make • Management Systems for Implementation
a difference have been clearly identified.” of Prevention Programs
— Chevril Wallace, Petrojam Ltd.
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13 Process Safety Management
Auditing Process Safety Management (PSM) Programs

Learn how to conduct and follow-up on a compliance audit for OSHA’s

Target Audience
PSM and EPA’s RMP regulations and/or other environmental, safety
Managers, supervisors and EH&S
and quality standards.
coordinators responsible for conducting
or managing compliance audits.
OSHA’s PSM and EPA’s RMP regulations specify that companies must perform
Course Description
periodic compliance audits and require documentation of their audit findings and
Prerequisite
action plans. Audits carry great significance, and must be planned and performed
An understanding of the prevention
with consideration of many factors.

program requirements of OSHA PSM or
This course provides a systematic, step-by-step approach to conducting an objec-

EPA RMP regulations. Alternatively,
tive, accurate audit. It covers all stages in an audit from planning and preparation
attendance at Primatech’s course
to follow-up on findings. Workshop exercises are used to develop auditing skills.

Developing and Implementing Process
Safety Management Programs.
Course Contents
• Regulatory Requirements for
PSM/RMP Auditing
• Overview of PSM/RMP Auditing
• Developing an Audit Program
• Preparation for an Audit
“This course was excellent. • Conducting an Audit
• Evaluating Compliance with OSHA’s PSM
The networking and practice-sharing Standard and EPA’s RMP Rule
was even better.” • Recording Audits
— Tyce Workman, Avery Dennison • Reporting on Audits
• Follow-Up on Audit Findings
• Quality Control in Auditing
• Issues in Using Audit Findings

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JSA, Procedure Writing 14
Job Safety/Hazard Analysis - Assessing Workplace Hazards

Learn how to use JSA to evaluate hazards in the workplace. Target Audience
Individuals involved with or responsible
Providing a safe workplace for employees is a fundamental responsibility of employ-

for occupational health and safety in an
Course Description
ers. Workers must be protected against industrial injuries and illnesses. Job Safety
organization.
Analysis (JSA) is a proactive method for identifying the potential for injuries and
incidents before they occur. It is often performed by first-line supervisors. As a pre-
Prerequisite
dictive technique, JSA is a highly desirable adjunct to compliance-based safety pro-

Knowledge and/or experience with safety,
grams or programs that are based on merely reacting to the occurrence of injuries and
health and environmental issues in the
incidents. It should be part of effective occupational safety and health programs.

workplace is desirable.
The course provides instruction on the use of JSA, sometimes called Job Hazard
Course Contents
Analysis (JHA). Attendees are taught how to identify jobs and tasks for analysis. In
• Overview
order to perform a JSA, users must understand the various workplace hazards which
• Understanding Workplace Hazards
are discussed in the course. The stages and steps in performing a JSA are described
• Performing a JSA
in detail with examples provided throughout. Attendees practice what they are taught
• Follow-Up
by performing exercises and participating in a workshop session where they conduct

• Implementing a JSA Program
a JSA to gain experience using the method.
The course concludes with a discussion of how to implement a program for perform-
ing JSAs within an organization. The use of the results of JSA to reduce workplace
risk is explained and examples are provided.
“Very informative
and will help greatly
in the continued
success of our
JHA program.”
— Jeff Brown, EES Coke Battery
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15 JSA, Procedure Writing
Principles of Procedure Writing

Learn how to develop and implement effective operating, Target Audience

maintenance, and other procedures. This includes the improvement Operations and Maintenance
of existing procedures. Personnel, Process Engineers,
Process Safety Personnel and others
who are responsible for the design
The development and use of effective and user friendly Operating and Maintenance
Course Description and development of procedures.
procedures in process facilities is essential for safe and efficient operations.

Written procedures are also a requirement of OSHA’s Process Safety Management
Prerequisite
(PSM) Standard, 29 CFR 1910.119. Procedures can have as much impact on

Experience in process operations,
process safety as the process equipment. The Operating Procedures element of the
maintenance, or process safety
PSM Standard is one of the most frequently cited elements by OSHA.

is desirable.
Many companies assume their employees can write procedures simply by docu-
Course Contents
menting what they do. However, this approach often produces ineffective proce-
• Overview
dures. There are much better approaches that can be used to write procedures that
do not require any more work than the traditional “write what you do” approach.
• Desirable Characteristics
These methods produce procedures that are much more effective and usable.
• Contents
• Organization and Structure
This course covers the fundamentals of writing effective procedures. You will learn
• Writing Procedure Steps
how to design and develop procedures according to established principles and best
• Format
practices and how to write procedures for their users. The regulatory requirements
• Level of Detail
for procedures are explained together with clarifications and interpretations from
• Selection of Procedures to Develop
OSHA. Throughout the course, examples and workshops are used to illustrate
properly (and improperly) designed procedures. While the emphasis in this course
is on operating and maintenance procedures, the course also applies to other facil-
ity procedures such as Safe Work Practices, Emergency Procedures, and Safety
Procedures.
The course manual includes resource materials to assist in designing and develop-
ing new procedures and reviewing and modifying existing procedures.
“The course gave me the knowledge,

skill and confidence to write very
good operating procedures.”
— Dave Rossi, TEPPCO

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JSA, Procedure Writing 16
Advanced Procedure Writing

Learn how to develop and implement effective and usable operating,

Target Audience
maintenance, and other procedures. This includes the improvement of Operations and Maintenance Personnel,
existing procedures. Process Engineers, Process Safety
Personnel and others who are responsible
The development and use of effective and user friendly operating and maintenance
for the design and development of
Course Description
procedures in process facilities is essential for safe and efficient operations. Written
procedures.
procedures are also a requirement of OSHA’s Process Safety Management (PSM)

Standard, 29 CFR 1910.119. Procedures can have as much impact on process safety
Prerequisite
as the process equipment itself. The Operating Procedures element of the PSM
Attendance at Primatech training course
Standard is one of the most frequently cited elements by OSHA.

Principles of Procedure Writing or equiva-
lent. Experience in process operations,
Many companies assume their employees can write procedures simply by document-
maintenance, or process safety is desirable.
ing what they do. However, this approach often produces ineffective procedures.
There are much better approaches that can be used to write procedures that do not
Course Contents
require any more work than the traditional ‘write what you do’ approach. These meth-
• Principles of Procedure Writing
ods produce procedures that are much more effective and usable.
• Human Factors in the Design
of Procedures
This course moves beyond the fundamentals of writing effective procedures covered
• Use of Syntax, Vocabulary
in the course Principles of Procedure Writing and covers more advanced issues in
and Punctuation
designing and developing procedures. The role of a management system for proce-
• Presentation of Numerical Information
dures is explained covering procedure design, development, implementation, mainte-

• Lists and Tables
nance and control. You will learn how to design procedures to ensure their usability.
• Conditional Statements
Guidelines are provided on various matters such as the appropriate use of language,
• Notes, Cautions and Warnings
numerical information, graphics, lists and tables. The writing of special types of pro-
• Cross References
cedural steps such as non sequential, continuous and time dependent is explained.
• Use of Graphics
Guidelines for drafting, evaluating and validating procedures are also covered.
• Special Types of Procedural Steps
Procedure maintenance, control and training are explained.

• Drafting Procedures
• Evaluating Procedures
The course provides guidelines for preparing several specific types of procedures
• Validation of Procedures
including standard operating procedures, safe work practices, emergency operating

• Accessibility and Use of Procedures
procedures, and maintenance procedures. Throughout the course, examples and work-
• Control of Procedures
shops are used to illustrate and apply the guidelines presented.

• Training Personnel Using Procedures
• Implementation of Procedures
The course manual includes resource materials to assist in designing and developing
• Guidelines for Preparing Specific
new procedures and reviewing and modifying existing procedures.

Types of Procedures
• Management Systems
“Take this class

and learn from
an expert.”
— Susan Stotts, BP America
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17 Human Factors and Human Errors
Principles of Human Factors for Process Safety

Learn how to identify and address important human factors Target Audience
issues in your plants. Process safety personnel, human
factors engineers and others who need
to understand human factors as it applies
Government regulations and industry recommended practices have focused atten-

Course Description to process safety.
tion on human factors in the process industries. OSHA’s PSM standard and EPA’s
RMP rule both address this topic. Human error as a cause of hazard scenarios must
Prerequisite
be identified and the factors that influence human errors must be considered. This
None
latter topic falls within the field of human factors engineering. It deals with the per-
son-process interface and how it influences the performance of people.
Course Contents
• Overview
Improving the human factors design of a process can produce not only improve-
ments in safety and health but also gains in quality and productivity.
for Human Factors
• Model of Human Factors in Processes
Usually, in process safety management the topic of human factors is addressed dur-
• Human Factors Issues in Processes
ing the performance of a process hazard analysis. However, PHA team members
• People
often have no background in human factors and are challenged by the assignment.
• Communications
This course is intended to provide process safety personnel with a better under-
• Process Equipment and Tools
standing and appreciation for the types of human factors issues that can impact on
• Displays, Controls and Alarms
process safety so that improvements can be recommended.

• Computer Hardware
• Computer Software
This course explains what is meant by human factors in the context of process safe-
• Procedures/Operating Instructions
ty. Regulatory requirements are discussed and clarifications provided. Explanations

• Rules and Practices
are provided and examples are given for the various aspects of human factors
• Job Tasks
involved in the interaction of people with processes so that attendees will be better
• Workplace/Workstation
able to identify such issues in their own processes in the future. Attendees are
• Control Room/Station
taught how to perform an assessment of the current human factors design of their
• Environment
processes.
• Organization
• Supervision/Management
• Human Factors Assessment Approaches
• Human Factors Design Guidelines
“Informative and eye-opening.”

— Everett Smith, Kaneka Texas Corporation

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Human Factors and Human Errors 18
Human Factors Methods for Process Safety

Target Audience
Understand the important elements of human factors for process safety Plant managers, design engineers, process
and receive guidance for their practical application in process plants. safety managers and coordinators, opera-
tions and maintenance engineers, and other
personnel who need to understand and apply
This course is intended for personnel who need an understanding of human factors
Course Description human factors methods to improve process
methods that can be used to improve process safety. Many companies have not prop-
safety.
erly addressed human factors in their process safety programs and this course pro-
vides the information needed to do so.
Prerequisites
None.
People are key components of processes. They are involved in process design, oper-
ation, maintenance, etc. No step in the process life cycle is without some human
Course Contents
involvement. Based on human nature, human error is a given and will arise in all
• Key Concepts
parts of the process life cycle. Also, processes are generally not well-protected from
human errors since many safeguards are focused on equipment failure. Consequently,
• Culture
it is likely that human error will be an important contributor to risk for most process-
• Leadership
es. This is evidenced by the number of major accidents that have been attributed to
• Policies and Procedures
this cause. Therefore, it is vital that the factors influencing the likelihood of errors be
• Facilities, Equipment, and Control Systems
identified and assessed to determine if improvements in the human factors of the

• Workstations
process are needed and possible.

• Equipment Design
• Signage and Labeling
The course covers key areas of human factors that are important for improving
• Control Centers
process safety in plants. Each area is explained, examples are provided, and available
• Human-Computer Interface
tools are identified. At the conclusion of the course attendees will have a tool kit to
• Alarm Management
comprehensively address human factors in process safety.

• Abnormal Situation Management
• Safety Systems
The course is taught by Dr. Paul Baybutt, one of the principal authors of the book,
• Safe Havens
• On-Site Roadways, Transportation
AIChE/CCPS, Wiley, 2007.

Human Factors Methods for Improving Performance in the Process Industries, and Traffic Control
• Environmental Factors
• People
• Training
• Communications
• Workloads and Staffing
• Shiftwork
• Competence
• Activities
• Design, Planning and Execution
• Operation
• Maintenance
• Safe Work
• Materials Handling
• Remote Operation
• Emergency Preparedness
and Response
• Hazard Analysis
• Risk Analysis
• Auditing
• Documentation
• Design and Use
• Procedures
• Permits
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19 Human Factors and Human Errors
Understanding and Applying Human Factors to Control Systems

Course Length: 1 day Accreditation: 0.7 CEUs
Learn how to design and improve the interface between operators Target Audience
and control systems to improve safety and operability. Personnel with responsibility for safe and
reliable plant operations.
The design of control systems in process and manufacturing plants directly impacts
the likelihood of human errors by operators. Human error is much more likely than
Knowledge of plant operations.
equipment failure. Consequently, the development of an optimized interface

between the process and equipment being controlled and the operators is vital for
Course Contents
ensuring safety and operability.

• Human Factors in Control System
Design and Operation
People control processes by interacting with process equipment. Human factors

• Aspects of Control Systems
issues for process equipment relate to how people interact with and use equipment.
• Equipment Design and Use
This entails studying the match between the attributes of people and those of equip-
• Control Center Design and Operation
ment that are involved in the interactions. Control rooms must be organized so that
• Human / Computer Interface
control room personnel are provided with an appropriate working environment.

• Operating Procedures
The likelihood of human errors in the control room and the likelihood that control
Development and Use
room personnel will be exposed to ergonomic hazards can be reduced by effective

• Documentation Design and Use
human factors control room design.

• Competence Management
The human/computer interface (HCI) deals with how people interact with comput-
er systems. Human failures in interacting with control systems can result in loss of
control and serious incidents. Various human factors issues are important in devel-
oping procedures. Also, a variety of documentation is used. Documentation design
can have a major impact on process safety and operability. Procedures that are not
followed, guidelines that are not used, diagrams that are misleading, and records
that are not completed properly can all increase the likelihood of accidents.
The ability of personnel to perform tasks according to expectations, or the compe-

tence of personnel, is crucial to every organization because of the role it plays in
ensuring tasks are carried out satisfactorily and safely. Competence should be man-
aged, otherwise poor performance and accidents may result.
The course identifies and describes tools available to address these important
human factors issues and provides instruction in their use.

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Human Factors and Human Errors 20
Human Error and Reliability Analysis

Learn how to identify the potential for human errors in processes and
Target Audience
how to determine the human factors that control their likelihood in Personnel with responsibility for safe
order to minimize accidents. process operations.
People will always make mistakes when interacting with processes. That is the nature
Course Description Prerequisites
of humans. Fortunately, human errors can be anticipated and protective measures

Prior experience or knowledge in process
taken against their occurrence. This requires the application of human factors engi-
safety is useful.
neering. It can yield major benefits in risk reduction and improved operability for
processes.
Course Contents
• Overview
In this course you will learn how to identify the potential for human errors in process-
• Human Factors Terms
es and how to determine the human factors that control their likelihood. Types of
• Nature of Human Errors
human errors are described and illustrated with examples and the factors influencing
• Regulatory Requirements for the
human errors are discussed. Classification schemes for use in the identification of
Treatment of Human Factors
human errors are provided. The classical human-machine model is described and an
• Importance of Treating Human Factors
improved person-process model is presented. Approaches to protect against human

and Human Errors in PSM
error are provided and their effectiveness discussed.

• Human Factors Engineering Review
(HFER)
The techniques described are presented in a step-by-step format together with guide-
• LOPA-HF
lines on how to perform the analyses. Examples are provided and attendees partici-
• Task Safety Analysis (TSA)
pate in workshop sessions to practice the techniques taught.

• Task Error Analysis (TEA)
• Issues in Human Factors for Managers
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21 MOC and Mechanical Integrity
Management of Change (MOC) for Process Safety

Learn how to establish a new or improve an existing MOC program. Target Audience
PSM Managers / Coordinators; MOC
The objective of a Management of Change (MOC) program is to ensure changes to a

Coordinators; Engineering and Maintenance
Course Description
process are properly reviewed and hazards introduced by the change are identified,
Personnel; and others who participate in
analyzed, and controlled prior to resuming operation. MOC often seems deceptively
decisions about process changes.
simple in concept but can be one of the most difficult elements of PSM to implement
effectively.
Prerequisite
Experience in PSM and/or managing
The course begins with a discussion of the types of changes that could have adverse
change is desirable. A background in Plant
impacts on process safety, including some that may not be obvious. Examples are
Engineering (Operations and / or
provided of how changes, including even very simple ones, have caused accidents.
Maintenance) is helpful.
Regulatory requirements for managing change are reviewed, including interpretations

and clarifications that have been provided by OSHA since the PSM standard was
Course Contents
issued.
• Overview
Management systems for managing changes are described and an example system is
provided. Keys to successful implementation of an MOC program are discussed and

• Designing and Developing a MOC
guidelines on establishing an effective MOC program are presented and applied in

Program
workshop exercises. Interfaces with other parts of the facility PSM program are iden-
• Types of Changes
tified.
• Personnel Roles and Responsibilities
• Interface with Other Facility Programs
The course manual includes resource materials to assist in developing a new MOC
• Elements of a MOC Program
program and reviewing/auditing and revising an existing MOC program.

• Implementation Guidelines
“An excellent course to get

up to speed on MOC.”
— Cristian Gonzalez, PSM Engineer, HOVENSA

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MOC and Mechanical Integrity 22
Mechanical Integrity (MI) for Process Safety and Risk Management

Learn how to satisfy regulatory requirements and improve safety and Target Audience
reliability by establishing or improving existing management systems, Operations and maintenance managers and
procedures and training programs for mechanical integrity (MI). engineers, and other personnel responsible
for mechanical integrity.
This course explains how to establish a new program or improve an existing program
for maintaining the integrity of critical process equipment to improve safety and relia-
A background in engineering and
bility. Participants learn how to satisfy regulatory requirements and improve reliability
maintenance is helpful.
by establishing or improving management systems, procedures and training programs

for mechanical integrity (MI).
Course Contents
• Overview
The course includes instruction on management systems for MI, determining what
equipment to include, identifying applicable codes and standards, deciding what repairs
and preventive maintenance should be performed, developing procedures, establishing

• Equipment Covered
requirements for the training of MI personnel, handling equipment deficiencies, and

• Codes, Standards and Practices
assuring the quality of equipment fabrication and installation and that spare parts and
• Maintenance Tasks
materials are suitable for their intended application.

• Procedures
• Managing Maintenance Hazards
Workshops and exercises are used to practice and reinforce the material covered in the
• Safe Work Practices and
course. A detailed manual is provided for use as a reference after you have completed
Permits-To-Work
the course.
• Training and Qualification of Personnel
• Preventive Maintenance Tasks
• Preventive Maintenance Frequencies
• Corrosion and Non-Destructive Testing
• Handling Equipment Deficiencies
• Quality Assurance
“I would recommend this (course)

to all maintenance personnel.
Very informative; it would be very
difficult to put together an
MI program without it.”
— Brian Pottloff, Maintenance Manager, Poet Biorefinery, LLC
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23 Process and Cyber Security
Process Security Management

Learn how to manage the risk of terrorist and criminal acts. Learn how Target Audience
to modify your current PSM program to address security and receive Process safety and security personnel, and
detailed implementation guidelines. others who may be responsible for manag-
ing the risk of threats to process facilities.
Plant or company managers looking to gain
OSHA’s Process Safety Management (PSM) Standard and EPA’s Risk Management
Course Description more understanding of threats and meth-
Program (RMP) Rule have resulted in improvements in managing accidental releas-

ods used to manage them at their facilities
es of highly hazardous chemicals. However, these regulations do not address releas-

would also benefit from taking this course.
es from deliberate acts. These acts can include threats of terrorism, sabotage, vandal-
ism and theft. Unless properly managed, it is possible that risk from deliberate acts
Prerequisite
could dominate that from accidental releases. This course deals with managing the
A general background in process safety,
risk from deliberate acts.

risk management and/or security at
manufacturing facilities is beneficial.
Events in the U.S. and overseas have emphasized the need for process security pro-
grams and both government and industry have acted to remedy shortfalls in process
Course Contents
security. This course describes a comprehensive program for process security man-
• Overview
agement that parallels process safety management (PSM) programs which address
• Types of Threats
accidental releases of hazardous materials. Such process security management pro-

• Industries/Facilities Subject to Attack
grams can reduce both the likelihood and the severity of terrorist and criminal acts.
• Common Chemicals and Their Effects
• Industry and Government Activities
Modeling process security management on process safety management offers numer-

• Legislation and Regulations
ous benefits. A considerable amount of development work has been performed and
• Management Systems for Process
experience accumulated on PSM programs since OSHA’s PSM standard was enacted
Security
in 1992. Most process companies invest significant resources in their PSM programs
• Coordination with Law Enforcement and
and value them highly. Modification of an existing program to address process secu-
Other Organizations
rity is easier and more efficient than developing a completely new program.
• Employee Involvement and Security
Furthermore, many companies already have in place elements of process security that
Awareness
can be integrated readily into an overall program.

• Process Security Information
• Security Vulnerability Analysis and
While PSM programs provide the framework for a comprehensive process security
Risk Assessment
management program, there are numerous significant differences requiring modifica-

• Security Measures and Safeguards
tions and additions to a PSM program to accommodate process security. This course
• Physical Site Security
presents an overall process security management program and describes these differ-
• Security of Computer Systems
ences. Detailed guidelines are provided for implementing each of the elements of the
• Control of Information
program.
• Security Procedures
• Training
• Systems Integrity
• Incident Reporting and Investigation
• Emergency Response and Crisis
Management
• Reviews, Audits and Inspections
• Legal and Insurance Issues

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Process and Cyber Security 24
Security Vulnerability Analysis (SVA)

Learn how to assess terrorist and criminal threats to facilities. Target Audience
Process safety and security personnel and
others who may be responsible for assess-
Process security management addresses threats from terrorist and criminal acts against
Course Description ing and managing the risk of threats to
plants that may result in the release of hazardous materials. The risk of such threats
process facilities.
must be assessed to determine if existing security measures and safeguards are adequate
or need improvement. Risk assessment is the heart of a process security program. It
Prerequisite
involves both threat analysis and vulnerability analysis.

Experience in qualitative risk analysis or
process hazard analysis is desirable.
Threat analysis is used to identify the sources and types of threats. Once specific threats
have been identified, vulnerability analysis is used to identify how threats could be real-
Course Contents
ized. Recommendations for consideration by management are made for improvements

• Overview
to reduce the likelihood and severity of terrorist and criminal acts based on the nature
• Risk and Decision Making
of the threat, process vulnerabilities, possible consequences, and existing security

• Threat Analysis
measures and safeguards. Risk rankings are performed as part of the analysis.
• Intelligence
• Source of Threats
This course describes a variety of available SVA methods including both asset and sce-
• Types of Threats
nario based methods. Attendees participate in workshop sessions where threat and vul-
• Ways to Realize Threats
nerability analysis is conducted.

• Guidelines for Identifying Threats
• Factors Affecting Threat Likelihood
• Assessment of Threat Likelihood
• Threat Levels
• Vulnerability Analysis
• Meaning of Vulnerability
• Steps in Vulnerability Analysis
• Preparation
• Conducting Studies
• Follow-up
• Lessons Learned
• Strategies for Security Measures and
Safeguards
• SVA Methods
• Rings of Protection Analysis (ROPA)
• Study Documentation and Reporting
• Follow-up on Action Items
• Cost-benefit Analysis for Security
Improvements
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25 Process and Cyber Security
Understanding and Applying Cyber Security for

Manufacturing and Computer Control Systems
Gain an understanding of cyber security and knowledge and tools that Target Audience
can be used to manage the risk of cyber attacks. Individuals involved with or responsible for
securing manufacturing and computer con-
Cyber security is an established discipline for computer systems used for business
trol systems from attack.
Course Description
management. Its focus is the protection of valuable information stored on those

systems from adversaries who want to obtain, corrupt, damage, destroy or prohibit
Prerequisite
access to it. Cyber security for manufacturing and control systems must also include
Knowledge and/or experience with either
protection against cyber or physical attack on computer systems and their support sys-
computer networks or manufacturing and
tems by adversaries who wish to disable or manipulate them to cause harm. Examples
computer control systems are helpful.
of manipulation include opening/closing valves, starting/stopping equipment, and

overriding alarm and trip settings. Traditional IT cyber security countermeasures are
Course Contents
not adequate to protect against attacks on control systems. Furthermore, such coun-
• Overview
termeasures may even compromise the safety or operability of manufacturing

• Current Initiatives
processes.
• Computer Networks and Control Systems
• Sources and Types of Attack
Historically, computer control systems have been kept separate from business and
• Vulnerabilities to Attack
enterprise computer systems but increasingly they are being connected through net-
• Attack Techniques and Tools
works, driven by the need to communicate process information to business groups and
• Cyber Security Countermeasures
the opportunity to intervene in manufacturing processes through an intranet or the

• Cyber Security Principles
Internet. Control systems are exposed to penetration when they are connected to other
• Human Factors in Cyber Security
networks or when there are provisions for remote access. Existing control systems
• Assessment Methods
were not designed with public access in mind, and often have poor security and are
• Cyber Security Program
vulnerable to attack. Furthermore, much of the technical information needed to pen-

etrate these systems is readily available.
This course provides attendees with an understanding of cyber security and knowl-
edge and tools that can be used to manage the risk of cyber attacks. It includes an
overview of the basics of computer networks and control systems for those attendees
who may not be familiar with them. Sources and types of attack, vulnerabilities,
attack techniques and countermeasures are described. The course concludes with a
discussion of how to implement a program to manage cyber security within an
organization.
“An excellent introduction to methods

and principles of the CSVA process.”
— Raymond Gray, Noveon/Lubrizol

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Process and Cyber Security 26
Cyber Security Vulnerability Analysis for

Manufacturing and Computer Control Systems
Receive step-by-step instruction in the use of CSVA methods to manage Target Audience
the risk of cyber attacks. Individuals who will participate in or lead
cyber security vulnerability analyses.
Many companies have conducted security vulnerability analyses (SVAs) to evaluate

Course Description
the risks of physical attacks on their facilities and many have been hardened since
Prerequisite
September 11, 2001. However, the importance of cyber security for manufacturing
Familiarity with computer networks and con-
and computer control systems has been recognized more recently. Appropriate secu-
trol systems. Knowledge of cyber security.
rity measures must be taken to avoid events which could have impacts as tragic as
Completion of Primatech’s training course,
those of September 11, 2001. Lesser cyber attacks have already occurred. Action is
Understanding and Applying Cyber Security
needed now to deal with this threat. Companies must conduct cyber security vulner-
for Manufacturing and Computer Control
ability analyses (CSVAs) to identify threats to their computer control systems, deter-
Systems, meets the prerequisites.
mine if vulnerabilities are present, and evaluate existing countermeasures to deter-

mine if they need to be strengthened or new ones implemented.
Course Contents
• Overview
This course provides step-by-step instruction in the use of scenario-based, asset-

• Target Analysis
based and sneak-path CSVA methods. Preparation, organization, recording, conduct-

• Threat Analysis
ing, reporting, and follow-up of CSVA studies are covered. Attendees apply CSVA
• Risk-Based Prioritization
techniques in workshop sessions.

(Facility Screening)
• Preparing and Organizing for CSVA
These methods can be used to conduct stand-alone CSVAs, CSVA as adjuncts to

• Subdividing the System
existing physical SVAs, or combined physical and cyber SVAs. They can be used to
• Recording Studies
address cyber (and physical security) not only for manufacturing and control systems
• Vulnerability Analysis Methods
but also for IT computer systems used in business management and computer sys-
• First CSVA Session
tems used in the value chain.

• Vulnerabilities
• Consequences
• Countermeasures
• Risk Ranking
• Recommendations
• Evaluating Countermeasures
• Reporting
• Follow-up
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27 In-House Training Courses
Schedule a Course at Your Site
About In-House Delivery

The Primatech Training Institute can deliver any Primatech training course to a group of employees at or nearby
your facility, including all of our publicly-available courses. In-house courses can be customized to include your
specific process examples. Please contact Primatech for additional details and assistance in meeting your training
requirements. The courses below are available for private, in-house delivery only.
Principles of PHA Updating Risk Management Plans (RMPs)
Principles of PHA helps participants gain an understanding of The Environmental Protection Agency’s (EPA) Risk
1 Day Course 1 Day Course
the regulatory requirements governing the performance of PHA Management Program rule (40 CFR Part 68) requires submission
and the techniques acceptable to OSHA and EPA. Guidance is of a Risk Management Plan (RMP) to the EPA. RMPs must be
provided on selecting PHA techniques and participating in a updated and submitted to the EPA at least once every five years.
PHA, and each of the techniques acceptable to OSHA and EPA This course explains how to ensure your RMP meets the require-
is described with examples. Attendees participate in the perform- ments of the Risk Management Program rule and discusses steps
ance of demonstration PHAs led by the course instructor using in the updating and resubmission of your RMP to the EPA.
the HAZOP and What-If techniques.
Probability and Frequency Analysis
This course explains how numerical estimates can be made of the

PHA Revalidation 1 Day Course
This course teaches participants how to revalidate previous frequency of accidents and the probabilities of the events that
1 Day Course
PHAs in accordance with the OSHA PSM and EPA RMP guide- contributed to them. The propagation of uncertainties in input
lines. Participants learn the most effective approaches to use in data through the analyses is explained. Sensitivities of the eval-
PHA updates and revalidations. The course also provides infor- uations to the input data are also described. Additionally, the
mation on recent regulatory interpretations and clarifications to ways in which the data developed are used in decision-making
assist in the identification and correction of possible omissions are described.
and deficiencies in the previous PHA.
Dispersion and Consequence Modeling
This course covers the basics of how to analyze the release of

Developing and Implementing 1 Day Course
chemicals from processes, their dispersion through the environ-

a Risk Management Program
This course explains how to comply with the requirements of ment and their toxic, fire and/or explosive effects. The develop-
2 Day Course
EPA’s Risk Management Program rule (40 CFR Part 68). There ment of results that can be used for risk-based decisions or input
are different requirements depending on whether the facility to further analyses is described.
qualifies for Program 1, 2, or 3 status. We explain which of
these apply to you, and show you how to develop the appropri-
ate program.
Continued on Next Page

PrimaT
7589.qxd 3/31/08 10:51 AM Page 29
In-House Training Courses 28
Coordination of the management of all these sureties is the pre-

ferred cost-efficient approach and helps avoid conflicts that can
Risk Analysis and Decision Making
This course explains how measures of risk are developed from arise between individual systems. The course provides guide-
1 Day Course
accident frequencies and consequences and how they are used lines and instruction applicable to all parts of a management
in decision-making. The various ways in which risk estimates system. Examples and practical exercises are included. You will
can be presented are covered. Comparison with tolerable also receive a model of a management system that can be used
risk criteria is also discussed. with any surety.
Understanding and Applying Management

Systems for Health, Safety, Security, Quality Designing and Implementing an Occupational
and Environmental Protection Health and Safety Management System (OHSMS)
Many organizations manage sureties such as safety, environ-

1 Day Course for the Workplace
mental protection, security, and quality using formal manage- Providing a safe workplace for employees is the fundamental
2 Day Course
ment systems. Management of such sureties is often addressed responsibility of employers. Workers must be protected from
by industry standards such as ISO 9000, ISO 14000, ISO workplace injuries and illnesses. Experience has shown that
22000, API RP750, and the Responsible Care Management successful health and safety management results from establish-
System (RCMS®) of the American Chemistry Council, and ing processes that address the multiple facets of safety within
government regulations such as OSHA’s Process Safety the context of a management system. Indeed, a British specifi-
Management standard and EPA’s Risk Management Program cation for a performance-based occupational health and safety
rule. Such management systems have many common elements management system (OHSAS 18001) has been developed. It is
and they all rest on a foundation of policies, procedures and compatible with ISO 9001 for quality management systems and
work instructions. People responsible for these systems must is the likely forerunner of an international standard. This
understand how to ensure these systems operate efficiently and course describes an Occupational Health and Safety
effectively. This training course addresses that need. Poorly Management System (OHSMS) tailored for US organizations
designed and operated programs result in wasted resources, and provides instruction on how to design and implement one
possible regulatory violations and can create legal liabilities. for your organization.
7589.qxd 3/31/08 10:51 AM Page 30
29 Primatech Software
A Global Leader in Process Safety Software
Primatech offers the following industry-leading software to help process

safety professionals do their jobs more efficiently and thoroughly.
PHAWorks® Learn more at www.primatech.com/software

Start documenting PHA studies in minutes
PHA (e.g., HAZOP, What If, FMEA) studies have become easier, quicker and more cost
effective with PHAWorks®. With the time and cost savings it provides, PHAWorks® is a
tool that is essential to your company. No program is used or trusted more throughout PHAWorks® Viewer
the world when completing PHA studies than PHAWorks®. Thousands of studies have
The PHAWorks® Viewer allows you to view
been completed worldwide using PHAWorks®.
any PHAWorks® or old DOS-Based (i.e.,
PHAWorks® is a specialized tool for conducting PHA studies from the smallest to largest
HAZOP-PC, WHAT IF-PC) project. You can
system. The design of the software allows you to start conducting studies straight out of
review projects and use features that don’t
the box and leads you through each step for conducting a PHA study. Within minutes,
alter or print any of the project informa-
tion. With PHAWorks® Viewer, anyone can
you can start documenting your PHA study more quickly and efficiently while keeping
the team focused on the task at hand.
review project data, but not change it. The
PHAWorks® Viewer is free and can be dis-
Companies have long been using PHAWorks® to complete PHA studies, but did you
tributed without any limitations.
know PHAWorks® can also be used for completing LOPA studies? It can also be used
to perform Security Vulnerability Analysis (SVA), Job Hazard Analysis (JHA), Task
Analysis, Human Factors Analysis, Checklist Reviews and many other types of studies.
Tracker …complete the commitment®

Learn more at www.tracker.primatech.com
Track action items from conception to completion
TrackerTM is designed to allow you to track recommendations and action

items from conception to completion. TrackerTM provides a tool most com-
panies are lacking — a consistent method for tracking items.
TrackerTM Includes
• Import/Export TXT and CSV Files
Companies have generated tens of thousands of action items, many of

• Import from PHAWorks® Projects
which have been lost or neglected. This is traceable to many companies

• Escalated Items
lacking a satisfactory tracking system. This leads facilities within the same
• Group Update
company to often use different systems / programs, resulting in added con-

• Link Files
fusion, inefficiencies, and lost items not to mention lost time and money.
• Generate Reports Across Multiple Files
• Custom Forms
TrackerTM provides the solution — a single preferred option for tracking

• Generate Custom Reports (Including Cost Reports)
items. TrackerTM is the tool to help ensure you avoid the risks and liability of
• Merge Tracked Items Together
forgotten or lost tracked items generated from multiple sources. Use

• Create Custom Fields
TrackerTM not only to manage the status of tracked items, but also as a man-
• File Information Such as Number of Items Overdue
agement tool to get up-to-date status reports and cost reports.

• Create Custom Source Types
• Create Custom Views (Activity and List)
TrackerTM consists of two key elements: TrackerTM and Tracker Client.

• Filter and Sort Tracked Items
TrackerTM is utilized by the individual(s) responsible for making sure the

• Schedule Requests and Reminders
tracked items are completed. Tracker Client is used by those who have
• Generate Requests Manually, Using E-mail or a File
tracked items assigned to them. Tracker Client users can receive updates on
• Close Completed Tracked Items
the tracked item and provide updates/feedback to the TrackerTM user.

• Built–in E-mail Program or Use Your Own
E-mail Program
• Use Responses as Final Resolution
• History of E-mails Sent and Received on Requests
• Customize the Form on Which Fields
to Use/Design
• Send Updated Data to PHAWorks® Projects

PrimaT
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Primatech Software 30
AUDITWorks TM
Learn more at www.primatech.com/software

Complete Safety, Health and Environmental Audits
AUDITWorksTM assists in the preparation and documentation of safety and

environmental compliance audits. The software provides guidance in conduct-
ing audits, a framework in which to record audit results including data man-
agement capabilities, and protocols for evaluating compliance.
Compliance Checklists Include
• OSHA PSM Compliance Directive Audit
AUDITWorksTM was designed to help you spend less time learning the soft-
Checklist (Instruction CPL 2-2.45A)
ware and more time conducting your audit. With its easy step-by-step
• OSHA PSM Standard Checklist
approach of proceeding into the audit worksheet, you’ll be conducting your

(29 CFR 1910.119)
audit within minutes. • Primatech OSHA PSM Checklist
A variety of checklists are available containing questions that can be used to

• EPA RMP Rule Checklist (40 CFR 68)
audit various programs, including OSHA’s Process Safety Management and

You can also import and customize your own
EPA’s Risk Management Program regulations. Audit against government reg-

checklists.
ulations, industry standards or your company’s own health, safety and envi-
ronmental standards. AUDITWorksTM provides the means to facilitate all
types of audits.
Consulting Services 30
Recognized Experts in Process Safety, Security and Risk
Primatech also offers professional safety, security and risk Primatech’s Consulting Services
consulting services. Capabilities Include
Companies that handle or process hazardous chemicals need to protect employees,

• Safety, Security and Risk Management
the public and the environment from exposure to accidental or deliberate releases.
• Cyber Security
Primatech provides consulting services to help companies reduce the likelihood

• Audits and Assessments (PSM / RMP)
and consequences of such releases. Measures taken to prevent releases also help
• Process Hazard Analysis (PHA)
improve productivity and quality and help meet regulatory compliance.

• Security Vulnerability Analysis (SVA)
Primatech’s consulting services range from conducting specific risk and safety
• Safety Instrumented Systems
analyses to providing support in establishing and maintaining comprehensive risk,

(S84 / IEC 61511)
safety and security management programs.

• Layers of Protection Analysis (LOPA)
• Facility Siting
We provide highly specialized assistance that’s not easily obtained elsewhere.

Whether leading a hazard analysis, performing a risk assessment, or modeling
• Human Factors and Human Error Analysis
release, dispersion and consequences, Primatech provides its expertise and tools
• Procedures Development
to help ensure accurate and useful findings. This helps clients realize substantial
• Mechanical Integrity
improvements in safety, security and risk while meeting industry standards and
• Dispersion and Consequence Modeling
satisfying government regulations.

• Release and Spill Assessment
• Quantitative Risk Assessment
• Probability Modeling
• Emergency Response Programs
• Expert Witness and Litigation Support
Visit
Visit www.primatech.com
www.primatech.com for
for current
current discount
discount offers
offers on
on training
training and
and software
software promotions.
promotions. 28
30
7589.qxd 3/31/08 10:51 AM Page 32
Te c h
PrimaT
Training Institute
50 Northwoods Blvd.,
Columbus, Ohio USA 43235
Telephone: 614-841-9800
Fax: 614-841-9805
www.primatech.com
training@primatech.com
Copyright © 2008, Primatech, Inc. All rights reserved.

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7589.

qxd 3/31/08 10:50 AM Page 1

TRAINING FOR PROCESS SAFETY,

1 Get The PTI Advantage!

Comprehensive Training The Best Training Available

Primatech Training Institute (PTI) provides compre- Comprehensive Training

In House Training Available Learn More

Multi-Course Discounts Consulting

Multi-Registration Discounts Register by Fax, Phone or Email

Copyright © 2008, Primatech, Inc., All rights reserved.

1 Te c h Training Institute | Visit www.primatech.com/training | Call (614) 841-9800 to Register

Courses Page Page

PROCESS HAZARD ANALYSIS (PHA) HUMAN FACTORS AND HUMAN ERRORS

Safety Integrity Level (SIL) Verification

Security Vulnerability Analysis (SVA) . . . . . . . . . . . .24

PROCESS SAFETY MANAGEMENT

Complete Safety, Health and Environmental Audits

CONSULTING SERVICES . . . . . . . . . . . . . . . . . . .30

3 Process Hazard Analysis

Process Hazard Analysis (PHA) for Team Leaders

ensure a successful study.

course, and instruction in the software is not included.

OSHA’s requirements for PHA team leaders.

3 Te c h Training Institute | Visit www.primatech.com/training | Call (614) 841-9800 to Register

Process Hazard Analysis 4

Advanced PHA for Team Leaders

Go beyond fundamentals to more advanced issues including the Target Audience

umented and applied. Companies should consider implementing these approaches

of the ANSI/ISA S84.01 standard on safety instrumented systems.

tion of control systems hazards than is possible with classical PHA.

“Excellent instructor with excellent

5 Process Hazard Analysis

Refresher Training for Process Hazard Analysis (PHA) Team Leaders

es and workshops are used to reinforce the material covered.

dards, resource materials, job aids and checklists.

Process Hazard Analysis (PHA) for Team Members

sessions. Participants gain an understanding of the regulatory and technical require-

dards, resource materials, job aids and checklists.

5 Te c h Training Institute | Visit www.primatech.com/training | Call (614) 841-9800 to Register

S84 / IEC 61511 and LOPA 6

S84 / IEC 61511 Standard on Safety Instrumented Systems (SIS)

S84.00.01-2004, Functional Safety: Safety Instrumented Systems for the Process

7 S84/IEC 61511 and LOPA

Layers of Protection Analysis (LOPA) for Process Safety Management

Layers of Protection Analysis (LOPA) is a simplified form of risk assessment. It

Process Industry Sector.

objective approach is needed, at least when considering risk remediation measures

oped for this purpose.

safety functions to protection layers, the determination of required Safety

Instrumented Functions (SIFs) and the determination of their Safety Integrity

“The course is quite outstanding; it is a must for all

7 Te c h Training Institute | Visit www.primatech.com/training | Call (614) 841-9800 to Register

S84 / IEC 61511 and LOPA 8

ANSI/ISA S84.00.01-2004, Functional Safety: Safety Instrumented Systems for the

cumstances. Methods include simulation, reliability block diagrams, cause-conse-

quence analysis, fault tree analysis, and Markov models.

Factors that should be included in the modeling include architecture; technology;

field device configuration; susceptibility to common cause failures; component

external influences. Workshops are used to practice the methods taught.

9 Process Safety Software

Learn how to best use PHAWorks® software, including all of its

PHAWorks® is a Windows-based computer software application that facilitates the

electronic recording of studies.