ProTrain Malaysia

Process Safety Training

Process Safety & Risk Management Training for High-Hazard Industries

Eight disciplines covering the full process safety lifecycle — from HAZOP and LOPA to emergency response, asset integrity and ALARP. All programmes are HRD Corp claimable (approved) and delivered by practising process safety engineers.

Request Training Proposal Browse the eight disciplines

Overview

One standard of practicality across every discipline

Each programme is built around workshops, real case studies and worked examples from operating plants — so participants leave able to run the study, not just describe it. Public sessions run across Malaysia and the region; every course can be customised for in-house delivery.

Discipline

Process Safety & Risk Management

Build a working command of PSM frameworks, LOPA, SIL, Bowtie and PHA so risk decisions are defensible — not just documented.

HRD Corp Claimable — where applicable

Process Safety Management (PSM) Fundamentals for Plant Leaders

3 days Classroom or in-house

A practical walk through the elements of process safety management — from process hazard analysis and operating procedures to mechanical integrity and management of change — anchored in real major accident case studies from Asian plants.

  • Explain each PSM element and how it fails in practice
  • Map your site's existing procedures against a recognised PSM framework
  • Identify the weak signals that precede major accidents

Who should attend: Plant managers, operations and maintenance managers, HSE leads

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HRD Corp Claimable — where applicable

LOPA, SIL and Bowtie Analysis — Applied Workshop

2 days Classroom or live online

Hands-on training in Layer of Protection Analysis, Safety Integrity Level determination and Bowtie visualisation, using worked scenarios from separators, fired heaters and storage systems.

  • Build a LOPA from a HAZOP scenario and assign credible IPLs
  • Determine SIL targets and understand what SIL does and does not mean
  • Construct a Bowtie diagram linking threats, barriers and consequences

Who should attend: Process engineers, safety engineers, risk analysts

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Discipline

Process Hazard Analysis

Train facilitators and participants to run HAZOP, HAZID, What-If, FMEA and ENVID studies that actually change design and operating decisions.

HRD Corp Claimable — where applicable

HAZOP Facilitation & Leadership

3 days Classroom

Covers HAZOP methodology end-to-end — node selection, guidewords, deviation analysis and action management — with participants facilitating live sessions on real P&IDs under coaching.

  • Plan and scope a HAZOP study, including team and documentation requirements
  • Facilitate deviation analysis without losing the room or the schedule
  • Write clear, assignable, closeable HAZOP actions

Who should attend: Prospective HAZOP leaders, process engineers, project engineers

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HRD Corp Claimable — where applicable

HAZID, What-If and FMEA for Early-Phase Projects

2 days Classroom or live online

When and how to apply HAZID, What-If checklists and FMEA at concept, FEED and modification stages — including ENVID studies for environmental hazard identification.

  • Select the right PHA technique for each project phase
  • Run a HAZID workshop from plot plans and block diagrams
  • Apply FMEA to equipment-criticality and spares decisions

Who should attend: Project engineers, design engineers, HSE professionals

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Discipline

Operational & Safety Management

Make MOC, Permit to Work, safe operating procedures and safety critical elements work on the ground — not just on paper.

HRD Corp Claimable — where applicable

Management of Change (MOC) and Pre-Startup Safety Review

2 days Classroom or in-house

Why MOC failures sit behind so many major accidents, and how to design an MOC process people actually use — including 'replacement in kind' traps, temporary changes and PSSR discipline.

  • Distinguish changes that need MOC from replacements in kind
  • Design an MOC workflow with the right technical review depth
  • Run an effective pre-startup safety review

Who should attend: Operations supervisors, engineers, maintenance planners

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HRD Corp Claimable — where applicable

Permit to Work and Safety Critical Elements in Practice

2 days Classroom

A field-level course on permit-to-work systems — isolation, gas testing, simultaneous operations — plus how safety critical elements and their performance standards connect to daily permits.

  • Identify where permit systems fail: handovers, SIMOPs, isolations
  • Link SCE performance standards to routine maintenance and permits
  • Coach work crews on stop-work authority and permit compliance

Who should attend: Permit issuers, operations and maintenance technicians, HSE officers

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Discipline

Incident & Emergency Management

Investigate incidents to their root causes, and prepare emergency response and crisis teams for the day it goes wrong.

HRD Corp Claimable — where applicable

Incident Investigation and Root Cause Analysis

3 days Classroom

Structured investigation methods — evidence preservation, timeline construction, causal factor charting and root cause analysis — applied to process safety events, not just personal injuries.

  • Secure a scene and preserve physical and documentary evidence
  • Build an evidence-based event timeline and causal factor chart
  • Write recommendations that address systemic root causes

Who should attend: Investigators, HSE professionals, line managers

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HRD Corp Claimable — where applicable

Emergency Response and Crisis Management for Industrial Sites

2 days Classroom with tabletop exercise

From on-scene emergency response to site crisis management: escalation levels, command structures, mutual aid and stakeholder communication, exercised through a realistic tabletop scenario.

  • Structure emergency and crisis teams with clear escalation triggers
  • Run a tabletop exercise and capture meaningful lessons
  • Manage regulator, media and community communication during a crisis

Who should attend: Emergency response team members, site leadership, crisis managers

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Discipline

Asset & Integrity Management

Keep containment: asset integrity, mechanical integrity, inspection and maintenance strategies aligned to risk.

HRD Corp Claimable — where applicable

Asset Integrity Management for Ageing Plants

3 days Classroom or in-house

How to build and run an asset integrity management system across the equipment lifecycle — design integrity, technical integrity and operating integrity — with emphasis on ageing and life extension.

  • Define integrity operating windows and manage exceedances
  • Structure an AIM system around safety critical equipment
  • Assess fitness-for-service and life-extension decisions

Who should attend: Integrity engineers, maintenance managers, plant engineers

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HRD Corp Claimable — where applicable

Risk-Based Inspection and Maintenance Strategy Development

2 days Classroom

Apply risk-based inspection thinking to prioritise inspection and maintenance spend — degradation mechanisms, consequence and likelihood assessment, and building a defensible inspection plan.

  • Identify credible degradation mechanisms by equipment type
  • Rank equipment by risk and set inspection intervals accordingly
  • Link RBI outputs to turnaround and maintenance planning

Who should attend: Inspection engineers, reliability engineers, planners

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Discipline

Fire, Explosion & Loss Prevention

Quantify and control fire and explosion risk — from hazardous area classification to QRA.

HRD Corp Claimable — where applicable

Fire and Explosion Risk Assessment for Process Facilities

3 days Classroom

Fire and explosion fundamentals applied to real layouts: fire scenarios, consequence modelling basics, passive and active protection, and how to interpret and challenge fire risk assessments.

  • Develop credible fire and explosion scenarios for your facility
  • Evaluate detection, isolation, passive protection and firewater provisions
  • Read and challenge a fire risk assessment or QRA report

Who should attend: Process safety engineers, HSE engineers, design engineers

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HRD Corp Claimable — where applicable

Hazardous Area Classification and QRA Essentials

2 days Classroom or live online

Practical hazardous area classification to recognised standards, plus the essentials of quantitative risk assessment — inputs, outputs, and what QRA results mean for siting and layout decisions.

  • Classify hazardous areas and select appropriate equipment ratings
  • Explain QRA inputs: leak frequencies, ignition, weather, occupancy
  • Apply risk contours to building siting and layout decisions

Who should attend: Electrical and instrument engineers, process engineers, designers

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Discipline

Human Factors & Safety Culture

Address the human side of process safety — organisational factors, leadership and culture that sustains safe performance.

HRD Corp Claimable — where applicable

Human and Organisational Factors in Process Safety

2 days Classroom or in-house

Why competent people make errors in well-run plants: human failure types, performance-influencing factors, procedure usability, fatigue and alarm management — and how to design work for humans.

  • Recognise human failure types and their different remedies
  • Assess procedures, interfaces and alarm loads for usability
  • Integrate human factors into investigations and PHA

Who should attend: HSE professionals, operations leaders, investigators

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HRD Corp Claimable — where applicable

Process Safety Leadership and Safety Culture Development

2 days Classroom

For leaders who set the tone: felt leadership, process safety metrics that drive the right behaviour, culture assessment, and how to respond to bad news so people keep bringing it to you.

  • Use leading and lagging indicators without gaming them
  • Run effective process safety site visits and conversations
  • Assess and strengthen your site's safety culture maturity

Who should attend: Site and corporate leaders, department heads, HSE managers

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Discipline

Major Accident & Loss Prevention

Manage major accident hazards end-to-end — consequence analysis, ALARP demonstration and risk-based decision making.

HRD Corp Claimable — where applicable

Major Accident Hazard (MAH) Management and Safety Cases

3 days Classroom

How to identify major accident hazards, build the barrier model around them, and demonstrate control through a safety case or equivalent regulatory submission — with regional regulatory context.

  • Identify MAH scenarios and map their barriers
  • Structure a safety case argument linking hazards to controls
  • Manage barrier health through performance standards and assurance

Who should attend: Process safety engineers, regulatory leads, asset managers

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HRD Corp Claimable — where applicable

Consequence Analysis, ALARP and Risk-Based Decision Making

2 days Classroom or live online

Consequence modelling essentials, ALARP demonstration and cost-benefit reasoning, and how to make transparent risk-based decisions when the answer is not obvious.

  • Interpret dispersion, fire and explosion modelling outputs
  • Build an ALARP argument with proportionate further measures
  • Apply a risk-based decision framework to real plant dilemmas

Who should attend: Risk analysts, process safety engineers, technical authorities

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Next Step

Need a process safety programme built for your plant?

Tell us the hazard study, incident pattern or competency gap you're dealing with and we'll scope an in-house programme around it — HRD Corp claimable where applicable.

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No obligation. Proposals include HRD Corp claim guidance.