Course Details

Objective

By the end of this course, participants will be able to:

• Understand the key safety standards and regulations relevant to plant operations.
• Learn how to identify and assess hazards in plant environments.
• Gain practical knowledge on implementing safe work practices and operational safety protocols.
• Understand the proper use of personal protective equipment (PPE) and safety devices in plant settings.
• Develop effective emergency response and incident management procedures.
• Promote a culture of safety and continuous improvement in plant operations.

Content

Day 1: Introduction to Safe Work Practices in Plant Environments

• Overview of safe work practices and their importance in plant safety.
• Key safety standards and regulations: OSHA, ANSI, and international standards.
• Identifying hazards in plant environments: Physical, chemical, ergonomic, and environmental risks.
• The role of safety culture in reducing workplace incidents.
• Implementing a safety management system (SMS) for plant operations.

Day 2: Hazard Identification, Risk Assessment, and Control

• Methods for identifying and assessing plant hazards: Walkthroughs, audits, and inspections.
• Understanding risk assessment and how to evaluate the severity and likelihood of incidents.
• Hierarchy of controls: Eliminating, substituting, engineering, administrative controls, and PPE.
• Implementing effective risk control measures: Safe work procedures and protocols.
• Conducting hazard analysis for routine and non-routine plant tasks.

Day 3: Personal Protective Equipment (PPE) and Safety Devices

• Types of PPE for plant workers: Head protection, eye protection, hearing protection, gloves, and respiratory protection.
• Selecting appropriate PPE for specific hazards and tasks.
• Proper maintenance, storage, and inspection of PPE.
• Overview of safety devices: Lockout/tagout (LOTO), emergency shutdown systems, and fire safety devices.
• Training workers on the correct use of PPE and safety equipment.

Day 4: Safe Operating Procedures and Plant Maintenance

• Developing and implementing safe operating procedures (SOPs) for plant tasks.
• Importance of Standard Operating Procedures in hazard control and worker safety.
• Routine maintenance and inspection practices to ensure safety and equipment reliability.
• Preventive and predictive maintenance strategies for reducing plant risks.
• Contractor safety management: Ensuring that external contractors follow plant safety practices.

Day 5: Emergency Response, Incident Management, and Continuous Improvement

• Emergency response planning: Fire, chemical spills, equipment failures, and first aid.
• Developing an emergency response plan (ERP) and conducting drills.
• Reporting and investigating incidents and near misses in the plant.
• Root cause analysis and corrective actions for preventing future incidents.
• Promoting continuous safety improvement: Safety audits, safety committees, and worker involvement in safety initiatives.

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions