NEBOSH PSM Exam Prep: Mastering Process Safety in Hazardous Industries

Provided by: Agile Leaders Learning and Development Department

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Occupational Health, Safety and Security Training Courses
NEBOSH PSM Exam Prep: Mastering Process Safety in Hazardous Industries

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Course Overview:

The course is designed to equip professionals with the essential skills and knowledge required to pass the NEBOSH Process Safety Management (PSM) exam and manage safety risks effectively in high-hazard environments. Drawing directly from the official NEBOSH HSE Certificate syllabus and structured to address real-world challenges across oil and gas, chemical, and manufacturing industries, this course integrates intensive exam preparation strategies, risk control methods, and applied safety systems.

Participants will delve into key topics such as process safety management systems, contractor safety management, emergency response planning, static electricity hazard control, and the FARSI model for safety-critical equipment. With modules rooted in UK and international safety regulations, learners will gain a robust understanding of process hazard identification (HAZID), Bowtie analysis, permit-to-work systems, thermal runaway prevention, and ALARP principles.

Target Audience:

HSE Managers and Supervisors
Process Safety Engineers
Health and Safety Consultants
Maintenance Managers
Site Operation Managers
Safety Trainers and Advisors
Industrial Risk Specialists

Targeted Organizational Departments:

Health, Safety & Environment (HSE)
Production and Operations
Risk Management & Compliance
Engineering & Maintenance
Chemical Safety Units
Process Safety Leadership Teams

Targeted Industries:

Oil and Gas
Chemical Manufacturing
Petrochemicals
Pharmaceutical Production
Industrial Processing Plants
Food and Beverage Manufacturing
Utilities and Power Generation

Course Offerings:

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

Interpret and apply the NEBOSH PSM syllabus to real industry scenarios
Identify and control process safety hazards
Implement process safety management systems effectively
Apply ALARP principles to reduce risk to acceptable levels
Analyse shift handovers, permit-to-work systems, and contractor safety plans
Develop performance indicators (leading and lagging) for process safety
Design emergency response plans aligned with COMAH standards

Training Methodology:

This course utilises a dynamic mix of practical, interactive, and theoretical learning strategies designed for adult professionals. Participants will engage in hands-on case studies drawn from real process industry incidents to simulate hazard identification (HAZID), Bowtie analysis, and FMEA exercises. Daily group work, role-play simulations, and instructor-led discussions on fire protection systems, emergency planning, and static electricity hazards help reinforce theoretical content with real-world relevance.

Course Toolbox:

NEBOSH PSM Study Guide (digital)
Process Safety Management Templates
HAZID and HAZOP Worksheets
FARSI Performance Standards Checklist
Recommended Reading List from NEBOSH and HSE
Online Case Studies and Reference Links

Course Agenda:

Day 1: Process Safety Foundations & Leadership

Topic 1: Introduction to NEBOSH Process Safety Management and syllabus overview
Topic 2: Understanding the difference between process safety and personal safety
Topic 3: Leadership responsibilities and the development of safety culture
Topic 4: Organisational learning from incidents, benchmarking, and knowledge management
Topic 5: Managing organisational change and its implications on safety
Topic 6: Worker consultation and contractor engagement principles
Reflection & Review: Discussion on leadership-driven safety improvements and lessons learned

Day 2: Managing Process Safety Risk

Topic 1: Establishing and implementing a Process Safety Management System (PSMS)
Topic 2: Risk assessment techniques and the ALARP principle in practice
Topic 3: Hazard identification and risk analysis tools: HAZID, HAZOP, Bowtie, FMEA
Topic 4: Asset integrity management and preventive maintenance strategies
Topic 5: Safe systems of work and permit-to-work procedures
Topic 6: Best practices in shift handovers and maintaining operational continuity
Reflection & Review: Real-world case review of process risk mitigation techniques

Day 3: Hazard Control and Operational Safety

Topic 1: Writing and maintaining effective operating procedures
Topic 2: Safe plant start-up, shutdown, and alarm system protocols
Topic 3: Safety critical equipment performance and the FARSI model
Topic 4: Utilities management: steam, water, and inert gases in process industries
Topic 5: Electricity and static electricity hazard control
Topic 6: Evaluating and managing contractor safety responsibilities
Reflection & Review: Group workshop on operating hazards and safety interventions

Day 4: Chemical Hazards, Bulk Storage, and Control Measures

Topic 1: Physical and chemical properties of dangerous substances
Topic 2: Thermal runaway reactions: causes, consequences, and containment strategies
Topic 3: Safe practices for bulk storage tanks and bunding systems
Topic 4: Siting and fire protection for storage facilities
Topic 5: COMAH regulations and compliance practices
Topic 6: Warehouse safety: segregation, ignition control, and weather protection
Reflection & Review: Application of chemical hazard control through simulated scenarios

Day 5: Fire and Explosion Risk, Emergency Response, and Exam Prep

Topic 1: Fire triangle, ignition sources, and explosion types in process industries
Topic 2: Fire detection systems and passive versus active protection methods
Topic 3: Dust explosion prevention, suppression, and zoning regulations
Topic 4: Emergency planning: roles, resources, and regulatory alignment
Topic 5: Public communication, evacuation, and table-top response drills
Topic 6: NEBOSH PSM mock exam walkthrough and key exam-taking strategies
Reflection & Review: Final summary, Q&A, and participant feedback

FAQ:

What specific qualifications or prerequisites are needed for participants before enrolling in the course?

While there are no formal prerequisites, it is recommended that learners have a foundational understanding of occupational safety and health. Prior NEBOSH General Certificate is a plus but not mandatory.

How long is each day's session, and is there a total number of hours required for the entire course?

Each day's session is generally structured to last around 4-5 hours, with breaks and interactive activities included. The total course duration spans five days, approximately 20-25 hours of instruction.

What is the FARSI model and how is it applied in safety-critical systems?

The FARSI model (Functionality, Availability, Reliability, Survivability, Interdependency) helps evaluate and maintain the integrity of safety-critical systems and equipment, particularly in preventing catastrophic process failures.

How This Course is Different from Other NEBOSH PSM Exam Prep Courses:

This course stands apart by delivering a high-intensity, results-oriented learning journey that not only prepares candidates for the NEBOSH Process Safety Management exam but also strengthens their ability to manage real-world safety risks across hazardous industries. Unlike typical PSM courses, this program offers deeper insights into process hazard identification, fire and explosion risk mitigation, and safety case development aligned with COMAH requirements. The use of scenario-based workshops (HAZOP, Bowtie, FMEA) and hands-on exercises allows learners to practice complex decision-making under realistic constraints.

ساعات معتمدة: 5 ساعة في اليوم

وضع الدورة: دوام كامل

مقدم الدورة: مركز (Agile Leaders) للتدريب