OSHA 1910.119 Process Safety Management (PSM) Training Course
- Duration
- 5 days
- CPD hours
- 15
- Language
- English
- Next date
- 19 Oct 2026
Overview
The OSHA 1910.119 Process Safety Management PSM Training Course from Institute For Oil & Gas Training develops the operational knowledge and risk management capabilities required to implement effective process safety management across oil and gas facilities handling highly hazardous chemicals. The course focuses on the OSHA PSM standard, process hazard analysis, process safety compliance, and the management systems that protect personnel, assets, the environment, and business continuity from major industrial incidents.
Oil and gas operations involve complex processes, pressurised systems, flammable substances, toxic materials, and interconnected equipment that demand rigorous process safety controls. Refineries, petrochemical facilities, gas processing plants, chemical storage terminals, and upstream production installations face significant operational risks when equipment integrity, process parameters, operating procedures, or management controls fall short of established requirements. Effective process safety management provides a structured approach to identifying hazards, controlling risks, maintaining safe operating conditions, and preventing catastrophic releases.
The OSHA 1910.119 standard establishes requirements for Process Safety Management of Highly Hazardous Chemicals in applicable workplaces. It addresses the prevention of catastrophic incidents involving toxic, reactive, flammable, or explosive chemicals through a comprehensive system of technical, operational, and organisational safeguards. Organisations operating under this framework require personnel who understand how individual PSM elements connect and how to translate regulatory requirements into practical workplace controls.
The course addresses the gap between understanding process safety requirements and applying them consistently throughout facility operations. Participants examine the relationship between process safety information, process hazard analysis, operating procedures, mechanical integrity, management of change, incident investigation, emergency planning, and compliance auditing. They develop the capability to evaluate existing systems, recognise weaknesses in safety controls, and support corrective actions that strengthen operational reliability.
For oil and gas organisations, process safety failures create consequences that extend beyond immediate equipment damage or production interruption. Major incidents expose employees and contractors to serious harm, threaten surrounding communities, cause environmental damage, and create significant financial and reputational consequences. A systematic approach to process safety compliance helps organisations identify vulnerabilities before they develop into major incidents and strengthens accountability across operational teams.
Institute For Oil & Gas Training delivers this course for professionals responsible for process engineering, operations, maintenance, technical safety, inspection, HSE, and regulatory compliance. The programme combines the requirements of OSHA 1910.119 with practical examples from hazardous industrial operations, enabling participants to understand how PSM principles apply to real operational decisions.
The training also emphasises the importance of leadership involvement, workforce participation, contractor coordination, and accurate safety documentation. Process safety is not solely the responsibility of the HSE department. It requires collaboration between management, engineering, maintenance, operations, procurement, and specialist technical teams. Participants explore how these functions contribute to hazard prevention and how effective coordination reduces the likelihood of unsafe operating conditions.
By completing the OSHA 1910.119 Process Safety Management PSM Training Course, participants gain a structured understanding of the regulatory framework and the practical controls supporting safe process operations. They leave better equipped to contribute to process hazard reviews, evaluate management systems, support audits, investigate incidents, and strengthen the implementation of process safety requirements within their organisations.
Objectives
Explain the purpose, scope, and principal requirements of the OSHA PSM standard in applicable industrial workplaces.
Interpret the responsibilities associated with managing highly hazardous chemicals and preventing catastrophic process incidents.
Identify the principal elements of process safety management and explain how they work together.
Evaluate process safety information covering chemical hazards, process technology, and equipment design.
Apply structured approaches to process hazard analysis and identify potential causes and consequences of hazardous process deviations.
Assess the effectiveness of safeguards and recommend appropriate risk reduction measures.
Understand the development, implementation, and maintenance of safe operating procedures.
Evaluate mechanical integrity arrangements for process equipment, safety systems, and critical components.
Apply management of change principles to technical, operational, organisational, and procedural modifications.
Explain the purpose of pre-start-up safety reviews and the conditions required before introducing hazardous materials into modified or new processes.
Recognise the responsibilities associated with contractor safety, workforce training, and employee participation.
Support incident investigation processes that identify underlying causes and establish effective corrective actions.
Assess emergency planning arrangements and their relationship with process hazard prevention.
Conduct structured reviews of PSM implementation and identify opportunities for stronger process safety compliance.
Improve communication between operations, engineering, maintenance, HSE, and management teams.
Develop practical recommendations for strengthening process safety performance and reducing operational risk.
Training methodology
Institute For Oil & Gas Training applies an industry-focused training methodology that connects regulatory interpretation with operational risk management. The course combines structured technical presentations, practical exercises, guided discussions, industrial case studies, and scenario-based problem-solving to help participants apply process safety principles in their working environments.
The delivery approach reflects the multidisciplinary nature of process safety management. Participants examine how engineering decisions, maintenance activities, operating practices, and management controls influence the safety of hazardous process facilities.
Regulatory Interpretation and Practical Application
Participants review the principal requirements of OSHA 1910.119 and explore their practical implications for organisations handling highly hazardous chemicals. Training activities focus on recognising the responsibilities associated with each PSM element, identifying required documentation, and understanding how regulatory expectations translate into operational procedures.
Examples demonstrate how organisations establish process safety information, conduct process hazard analysis, manage equipment changes, and verify the implementation of corrective actions. This approach helps participants distinguish between maintaining documentation and operating an effective process safety management system.
Industrial Case Studies
Case studies draw on common process safety challenges in refineries, petrochemical plants, gas processing facilities, and other hazardous industrial environments. Participants examine scenarios involving loss of containment, equipment deterioration, inadequate operating procedures, uncontrolled modifications, and weaknesses in safety-critical communication.
Each case study encourages participants to identify contributing factors, evaluate existing safeguards, and determine which PSM elements support prevention. The emphasis remains on understanding how incidents develop and how systematic controls prevent similar failures.
Process Hazard Analysis Exercises
Participants work through representative hazard scenarios using recognised techniques such as Hazard and Operability Studies, What-If Analysis, and Failure Mode and Effects Analysis where appropriate to the application. They identify hazardous deviations, examine potential consequences, assess existing safeguards, and consider recommendations for reducing risk.
These exercises develop an understanding of process hazard analysis as a continuing risk management activity rather than a documentation exercise completed only to satisfy a compliance requirement.
Management System Simulations
Scenario-based exercises address management of change, mechanical integrity, incident investigation, and compliance auditing. Participants evaluate proposed process modifications, review hypothetical equipment deficiencies, investigate deviations from established procedures, and identify weaknesses in management controls.
Group discussions demonstrate how decisions in one department influence the responsibilities of other teams. Participants learn to assess changes systematically, document decisions, establish appropriate safeguards, and verify the completion of corrective actions.
Collaborative Problem-Solving
Group activities encourage participants to consider operational problems from engineering, maintenance, production, HSE, and management perspectives. They discuss responsibility allocation, communication arrangements, contractor interfaces, and the importance of workforce participation.
This collaborative approach strengthens the ability to coordinate process safety activities across organisational boundaries. It also helps participants recognise the role of leadership, competent personnel, reliable information, and consistent follow-through in maintaining effective PSM systems.
Workplace Application
Throughout the course, participants relate the subject matter to their own facilities, operating procedures, equipment, and organisational responsibilities. They identify practical opportunities to improve hazard identification, documentation quality, audit readiness, and corrective action management.
The training concludes with an integrated review of process safety management, allowing participants to connect the individual regulatory elements into a coherent system for preventing major process incidents.
Organisational impact
Effective application of process safety management improves the way oil and gas organisations identify, assess, control, and monitor hazards associated with industrial processes. By developing employee competence in OSHA 1910.119, organisations strengthen the systems that protect people, equipment, production assets, and surrounding communities.
Stronger Process Safety Compliance
Participants develop a clearer understanding of regulatory requirements and the documentation needed to demonstrate the implementation of relevant PSM elements. This supports more consistent internal reviews, improved evidence management, and more systematic identification of compliance gaps.
Organisations benefit from better coordination between regulatory obligations, operating procedures, technical records, and corrective action programmes. These improvements support audit preparation and provide management with a clearer view of process safety system performance.
Improved Hazard Identification and Risk Control
A structured understanding of process hazard analysis helps personnel recognise potential failure scenarios before they result in uncontrolled releases or hazardous operating conditions. Participants learn to examine deviations, identify contributing factors, evaluate safeguards, and support risk reduction recommendations.
This approach strengthens preventive decision-making and improves the quality of risk assessments used in engineering, maintenance, and operational planning.
Reduced Potential for Major Incidents
Effective PSM implementation establishes multiple layers of protection against major industrial incidents. Better operating procedures, stronger equipment integrity controls, appropriate change management, and effective incident investigation reduce exposure to preventable process hazards.
Training supports the consistent application of these controls by improving employee understanding of the systems that prevent catastrophic releases, fires, explosions, and toxic exposures.
Greater Equipment Reliability
Mechanical integrity and quality assurance are important components of safe process operations. Personnel who understand inspection requirements, equipment deficiencies, testing arrangements, and maintenance responsibilities contribute to better management of safety-critical equipment.
Organisations gain a stronger basis for identifying deteriorating conditions, prioritising maintenance interventions, and ensuring that equipment remains suitable for its intended operating conditions.
More Effective Management of Change
Changes to equipment, chemicals, process conditions, software, operating procedures, or organisational arrangements introduce risks when they are not adequately assessed. The course reinforces the importance of reviewing proposed changes before implementation, evaluating their safety implications, updating documentation, and communicating revised requirements.
These practices reduce the likelihood of uncontrolled modifications creating new hazards or weakening existing safeguards.
Improved Incident Learning
A systematic incident investigation process enables organisations to move beyond immediate causes and examine weaknesses in equipment, procedures, training, supervision, and management systems. Participants develop an understanding of how findings support corrective actions and prevent recurrence.
The result is a more disciplined approach to incident learning, action tracking, and organisational improvement.
Better Coordination Across Departments
Process safety management depends on effective communication between operational and technical functions. The course helps establish a shared understanding of responsibilities among engineering, operations, maintenance, HSE, contractors, and senior management.
This alignment improves the flow of safety information, clarifies accountability, and supports more consistent decision-making across the facility.
Stronger Operational Continuity
Preventing major process incidents and managing equipment risks effectively supports reliable production. Better hazard controls and disciplined operating practices reduce exposure to avoidable shutdowns, emergency interventions, equipment damage, and unplanned operational disruption.
Organisations can evaluate improvements through indicators such as overdue corrective actions, audit findings, equipment integrity deficiencies, management of change completion, and recurring process safety incidents. These measures help management assess the effectiveness of improvement initiatives without relying on unsupported performance guarantees.
Improved Management Oversight
Senior personnel gain a stronger basis for reviewing PSM performance, allocating resources, and monitoring the implementation of corrective actions. Clearer reporting and defined responsibilities help management identify weaknesses requiring attention and maintain oversight of significant process risks.
Personal impact
The course strengthens the technical understanding and practical judgement of professionals responsible for hazardous process operations. Participants develop capabilities that support their existing responsibilities and prepare them to contribute more effectively to process safety improvement initiatives.
Improved Understanding of OSHA Requirements
Participants gain a structured understanding of OSHA 1910.119, including its scope, core requirements, and principal management system elements. This knowledge supports more confident discussions with technical specialists, auditors, managers, and operational teams about applicable process safety obligations.
Greater Process Hazard Analysis Capability
Participants learn how to identify process deviations, examine hazardous scenarios, review safeguards, and support structured risk assessments. They become better prepared to contribute to hazard review meetings and evaluate the significance of recommendations arising from process hazard analysis.
Stronger Technical and Operational Judgement
The training develops the ability to connect technical information with operational decisions. Participants learn to recognise when changes, equipment deficiencies, procedural weaknesses, or abnormal operating conditions require formal assessment and escalation.
This capability supports more disciplined decisions and reinforces the importance of established safety controls.
Improved Audit and Documentation Skills
Participants develop a clearer understanding of PSM documentation, compliance reviews, audit findings, and corrective action records. They gain practical insight into identifying missing evidence, evaluating the completeness of management system records, and tracking actions through to verification.
Enhanced Incident Investigation Skills
The course strengthens participants understanding of systematic incident investigation and the importance of identifying underlying causes. They learn to distinguish immediate events from broader organisational weaknesses and to connect investigation findings with preventive actions.
Better Cross-Functional Communication
Participants gain a stronger appreciation of the responsibilities of engineering, maintenance, operations, HSE, and management personnel. This supports more effective collaboration when reviewing hazards, approving changes, resolving equipment issues, and implementing corrective measures.
Increased Professional Capability
Knowledge of process safety management strengthens the professional capabilities of personnel working in process engineering, operations, maintenance, inspection, HSE, and risk management. Participants gain a more comprehensive view of how technical safeguards and management systems contribute to safe facility performance.
Greater Confidence in Process Safety Responsibilities
Participants become better equipped to recognise process safety concerns, raise issues through appropriate channels, contribute to structured reviews, and support improvement plans. They also develop a clearer understanding of when specialist engineering assessment or formal management approval is required.
Who should attend
Operations Managers and Supervisors: Strengthen oversight of operating procedures, process deviations, workforce responsibilities, and safe operating conditions.
Process Engineers: Improve their understanding of process safety information, hazard analysis, technical safeguards, and process modifications.
HSE Managers and Officers: Develop stronger capabilities in PSM implementation, compliance monitoring, incident investigation, and safety improvement planning.
Process Safety Engineers and Specialists: Consolidate their understanding of PSM requirements and the coordination of individual management system elements.
Maintenance Managers and Engineers: Improve the integration of mechanical integrity, inspection findings, equipment reliability, and maintenance controls with process safety objectives.
Inspection and Asset Integrity Professionals: Understand how equipment condition, inspection programmes, and technical deficiencies influence process safety risks.
Plant and Facility Managers: Strengthen management oversight of operational hazards, compliance priorities, resource allocation, and corrective action implementation.
Production and Refinery Personnel: Develop a clearer understanding of the safety controls governing hazardous processes and abnormal operating conditions.
Oil and Gas Project Managers: Understand process safety considerations during project development, facility modification, commissioning, and operational handover.
Engineering Managers: Improve coordination of process design, technical reviews, management of change, and safety-critical engineering decisions.
Risk Management Professionals: Strengthen their ability to connect hazard identification, risk assessment, safeguards, and risk reduction actions.
Compliance and Internal Audit Personnel: Improve their understanding of PSM requirements, documentation, audit evidence, and compliance gap identification.
Technical Safety Professionals: Develop a broader understanding of how process safety analysis, protective systems, and management controls interact.
Contractor Management Personnel: Strengthen contractor coordination, hazard communication, work control, and understanding of site-specific process safety responsibilities.
Senior Managers and Department Heads: Improve strategic oversight of major process risks, organisational accountability, and process safety performance.
Professionals Transitioning into Process Safety Roles: Establish a structured foundation in PSM principles and their application to oil and gas operations.
Course outline
This module establishes the regulatory and operational foundations of process safety management. Participants examine the purpose of OSHA 1910.119, the management responsibilities associated with hazardous processes, and the relationship between technical safeguards and organisational controls. The module also establishes how the scope of a PSM programme is determined for applicable processes involving highly hazardous chemicals.
-
OSHA Hazard Communication Standard
Establishes requirements for communicating information about chemical hazards in applicable workplaces.
Addresses chemical hazard classification, labels, safety data sheets, and employee information and training.
Supports the communication of chemical hazards within broader process safety arrangements.
Complements process safety management by helping personnel understand the hazardous properties of substances used in industrial operations.
Learning Outcomes
Explain the purpose and principal requirements of OSHA 1910.119.
Identify processes and workplace conditions requiring careful assessment of PSM applicability.
Describe the responsibilities of employers, employees, contractors, and management.
Explain how the 14 PSM elements support the prevention of major process incidents.
Identify the principal records and procedures supporting PSM implementation.
Recognise the importance of leadership, workforce participation, and cross-functional accountability.
This module focuses on developing an accurate understanding of process hazards and evaluating scenarios that threaten safe operations. Participants examine the information required to understand chemical properties, process technology, and equipment design. They then explore structured process hazard analysis methods used to identify hazardous deviations, assess consequences, and recommend safeguards.
-
IEC 61882 Hazard and Operability Studies
Provides guidance on the application of Hazard and Operability Studies to identify hazards and operability problems.
Describes a structured approach using guidewords, process parameters, deviations, and their possible consequences.
Supports systematic examination of process risks and existing safeguards.
Provides a recognised methodology for process hazard studies that complements applicable PSM requirements.
Learning Outcomes
Identify the principal components of process safety information.
Explain how chemical, process, and equipment information supports hazard identification.
Describe the purpose and application of recognised process hazard analysis techniques.
Identify process deviations, potential consequences, and existing safeguards.
Evaluate the importance of documenting findings and prioritising recommendations.
Explain the requirements for reviewing process hazard analysis findings and tracking corrective actions.
Recognise how human factors and facility design influence process risk.
This module examines the operational and organisational controls that maintain safe conditions throughout the process lifecycle. Participants review the role of written operating procedures, employee training, contractor coordination, and formal management of change. The module also addresses pre-start-up safety reviews and the importance of verifying readiness before introducing hazardous materials into new or modified processes.
-
OSHA Control of Hazardous Energy
Establishes requirements for controlling hazardous energy during servicing and maintenance activities in applicable workplaces.
Addresses energy isolation, lockout and tagout procedures, and the protection of personnel from unexpected equipment energisation or hazardous energy release.
Supports safe maintenance practices that interface with operating procedures and process safety controls.
Requires suitable procedures and employee training within its applicable scope.
Learning Outcomes
Explain how operating procedures support safe and consistent process operations.
Identify the operating phases that require clearly defined instructions and safeguards.
Describe training and contractor management responsibilities under PSM.
Evaluate the principal steps in a management of change process.
Identify the information, approvals, and communications required before implementing changes.
Explain how pre-start-up safety reviews confirm readiness for new or modified processes.
Recognise the importance of energy isolation and safe work practices during maintenance.
Identify weaknesses in operating procedures, training records, and change management documentation.
This module addresses the condition, reliability, and maintenance of equipment used in hazardous process operations. Participants examine mechanical integrity requirements and the role of inspection, testing, preventive maintenance, quality assurance, and deficiency management. The module connects equipment reliability with process safety by demonstrating how degradation, unsuitable replacement parts, inadequate testing, and delayed corrective actions increase the risk of loss of containment or protective system failure.
-
API 510 Pressure Vessel Inspection
Establishes recognised inspection, rating, repair, and alteration practices for applicable in-service pressure vessels.
Supports assessment of vessel condition and continued suitability for service.
Provides a technical framework for inspection and repair decisions within its scope.
Complements mechanical integrity programmes by supporting the management of pressure equipment risks.
Learning Outcomes
Identify equipment categories addressed by mechanical integrity requirements.
Explain the importance of inspection, testing, maintenance, and quality assurance.
Recognise common equipment deficiencies that threaten process safety.
Describe how maintenance priorities relate to equipment condition and process risk.
Evaluate the importance of accurate inspection records and documented acceptance criteria.
Explain how replacement parts and repair activities affect equipment integrity.
Identify the interfaces between mechanical integrity, safe work practices, and operating procedures.
Recommend practical improvements to equipment deficiency reporting and corrective action management.
This module brings together the principal PSM elements through incident learning, emergency preparedness, compliance verification, and continuous improvement. Participants examine how organisations investigate process incidents, identify underlying causes, assess emergency arrangements, and verify the implementation of safety management requirements. The module also considers the role of audits, corrective action tracking, and management oversight in maintaining effective process safety controls.
-
NFPA 1600 Emergency Management
Provides a recognised framework for emergency management, preparedness, response, recovery, and business continuity.
Supports the development and evaluation of organisational emergency management arrangements.
Encourages coordinated planning, defined responsibilities, and appropriate exercises.
Complements process safety emergency planning while remaining distinct from the specific requirements of OSHA 1910.119.
Learning Outcomes
Explain the purpose and principal steps of a process safety incident investigation.
Identify underlying causes and develop appropriate corrective actions.
Describe the role of emergency planning and coordination in hazardous process facilities.
Explain how PSM compliance audits assess implementation of applicable requirements.
Identify documentation and operational evidence relevant to audit findings.
Establish clear corrective action responsibilities and verification arrangements.
Recognise useful indicators for monitoring process safety management performance.
Develop practical recommendations for improving PSM implementation across the organisation.
Certificate
Upon successful completion of the OSHA 1910.119 Process Safety Management PSM Training Course, attendees receive a Certificate of Completion from Institute For Oil & Gas Training.
The certificate recognises completion of the training programme. Attendees must satisfy the course attendance requirement and participate in the required training activities to qualify for the certificate. Completion of this course does not, by itself, confer an OSHA-issued qualification, professional licence, or regulatory authorisation.
Course dates
Fees include tuition, course materials and refreshments. Need different dates or a different city? Ask about your preferred date.
Frequently asked questions
What is the OSHA 1910.119 Process Safety Management PSM Training Course?
The course provides practical training in the requirements and implementation of OSHA 1910.119, the Process Safety Management of Highly Hazardous Chemicals standard. It covers process safety information, process hazard analysis, operating procedures, mechanical integrity, management of change, incident investigation, emergency planning, and compliance auditing. The programme is designed to help oil and gas professionals strengthen their understanding of process safety controls and their responsibilities within hazardous industrial operations.
Who should attend this process safety management training course?
The course is suitable for operations managers, process engineers, HSE professionals, maintenance personnel, inspection specialists, plant managers, technical safety engineers, compliance auditors, project managers, and other professionals responsible for hazardous process operations. It also benefits senior managers who oversee operational risk, regulatory compliance, and process safety performance.
What will participants learn about process hazard analysis?
Participants learn how process hazard analysis identifies hazardous deviations, examines potential consequences, evaluates existing safeguards, and supports risk reduction decisions. The course introduces recognised approaches such as Hazard and Operability Studies, What-If Analysis, and Failure Mode and Effects Analysis where appropriate. It also addresses documentation, recommendation tracking, and the importance of reviewing analysis findings when processes change.
How is the OSHA PSM training delivered?
Institute For Oil & Gas Training uses an industry-focused approach combining technical presentations, industrial case studies, scenario-based exercises, group discussions, and practical reviews of process safety management activities. Participants examine realistic operational challenges involving equipment integrity, operating procedures, management of change, incident investigation, and compliance auditing. The overall course duration is 15–20 hours, with activities structured around the five course modules.
Does completing the course provide an OSHA qualification or certification?
Participants who complete the training and satisfy the attendance requirement receive a Certificate of Completion from Institute For Oil & Gas Training. This confirms completion of the course but is not an OSHA-issued qualification, professional licence, or regulatory authorisation. The training develops practical knowledge of OSHA 1910.119 and supports participants in applying relevant process safety management principles within their organisational responsibilities.
Register your interest
OSHA 1910.119 Process Safety Management (PSM) Training Cours...
No payment is taken here. We reply within one working day with availability and a formal quotation.
Next: 19 Oct 2026
4 dates available