Technical Training
Technical Training
Technical Training
ABB LIMITED
Technical training
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To request our current list of our
open courses or for any other
training query, please email:
[email protected] and we will be
happy to help you.
A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G TECHNICAL TR AINING 3
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Contents
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An introduction to ABB
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Our approach to technical training
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In-company courses or open dates
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ABBreviations
FMECA
Failure Modes Effects
and Criticality Analysis
RCA
Root Cause Analysis
SIL
Safety Integrity Levels
LOPA
Layer of Protection Analysis
ATEX HAZOP
ATmospheres EXplosives HAZard and OPerability study
DSEAR
Dangerous Substances and
Explosive Atmospheres Regulations
SIF PSM
Safety Instrumented Functions Process Safety Management
8 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Booking and contacts
Cancellations made up to 28 days prior to Please note: For courses held in hotel
the event will be subject to an venues: If you request overnight
administration fee of £50. Cancellations accommodation at the hotel and then
made 27-14 days prior to the event will be choose to cancel less than 2 weeks prior
subject to a cancellation fee of 50%. to the event, then it is your responsibility
Cancellations made thereafter will be to pay any cancellation fees. Any event
subject to the full event fee, however a fee already settled will be refunded if the
substitute delegate can be named at any event is cancelled by ABB. Travel
time. expenses will not be covered.
Prices apply to bookings made prior to For courses held in ABB locations: ABB
31st December 2018. Payment is due at withholds the right to cancel the event up
the end of the month following the date to one week before the event. Therefore,
of the training course. Accommodation is we recommend any accommodation and
not included in the prices. travel bookings are flexible.
10 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Meet some of our tutors
Graeme Ellis
Specialist Safety Consultant
Chris Flower
Chemical Engineering Specialist
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Course index
Asset integrity X X
Electrical awareness X X
14
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Process safety
15
16 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Achieved Safety Integrity Level (SIL)
Day 1 agenda*
Registration and coffee
Introduction
SIL as part of functional safety
–– Why do we need functional safety and safety instrumented systems?
–– Functional safety standards; IEC61511 and IEC61508
–– ‘Three Steps’ to SIL; SIL Determination, Achieved SIL, Operations and Maintenance
Setting the target SIL
–– Risk and risk reduction
–– Reminder of hazard identification and SIL determination
Safety requirement specification
–– Information to be specified to design group or external company
Designing a Safety Instrumented Function
–– Safe and dangerous failures
–– The relationship between instrumentation and SIL
–– Use of basic calculations
–– Humans and alarms as part of Safety Instrumented Functions
–– Importance of dangerous failure rates for instrumentation
–– Instrument data sources and instrument certificates
Summary and conclusions
Close
Day 2 agenda*
Review of Day 1
Testing as part of the SIF Design
–– High and low demand rate safety functions
–– Time to test and errors introduced during testing
–– Relationship between PFDavg, instrument failure rates and test intervals
Advanced architectures (1oo2, 2oo3) and constraints
–– Calculations
–– Hardware fault tolerance
–– Diagnostic coverage and safe failure fraction
–– More on manufacturers certificates
–– Systematic controls
–– Common cause and common mode failures
–– Sharing equipment between SIF and Control system
–– Testing final elements and partial testing
Installation and commissioning
–– Validation, verification, audits and functional safety assessment
Operate and Maintaining the Safety Instrumented Functions
–– Proof testing requirements
–– O verrides and bypasses
–– Maintenance and modification
–– Importance of recording and reviewing demands and test results
Review and feedback
Close
*ABB reserve the right to amend the course agenda.
18 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Advanced hazard assessment
techniques for SIL determination
Management of risk and the demonstration
In-company / open course Yes / Yes
of appropriate risk reduction measures are
Duration 5 days
becoming increasingly important in
industry today. This can be relevant to
compliance with aspects of legislation, such –– Basic human error assessment
as COMAH, and in the application of –– Applying basic SIL and hazard assessment
standards such as IEC 61508 and IEC 61511. in a variety of situations to help in making
more effective and cost effective
This course is designed for those who need decisions
to understand the causes and sequence of
failure that can lead to significant This course is also suitable as a basic
hazardous events occurring and be able to qualification for those wanting to become
identify the key contributors to the level of hazard and reliability analysts.
risk - to people, business or the
environment. Who will benefit and what will they gain?
The effective use of the techniques allows
Topics include: questions to be answered in the areas of
safety, health and environment; asset
–– Calculation of hazardous event management and maintenance; loss
frequencies prevention; new investment. Typical
–– Assessment of risk reduction from attendees would be:
protective systems and Safety Integrity
Levels (SIL) –– Process design engineers
–– Criteria for tolerable levels of risk –– Electrical, control and instrument
–– Assessment of demand frequence on engineers
protective systems –– Safety managers and advisors
–– Works or technical managers with
What the course will cover? responsibility for managing risk
On completion of the course you should be –– Leaders of HAZOP studies
able to demonstrate a working knowledge
of SIL and hazard assessment including: Typical attendees would probably have:
–– Some experience of design and plant
–– Logical analysis, using fault tree operation
techniques of scenarios leading to –– An analytical and structured approach to
hazardous events problem solving
–– Use of data and its application to predict
the likelihood of a hazardous event
–– Development of practical hazard criteria
–– Handling of dependent or common mode
failures
NOTE: This course was previously titled SIL determination
and hazard assessment.
A D VA N C E D H A Z A R D A S S E S S M E N T T E C H N I Q U E S F O R S I L D E T E R M I N AT I O N 19
Day 1 agenda*
–– Registration and coffee –– Risk assessment
–– Introduction –– Consequence assessment
–– International standards - IEC 61508/61511 –– Layer of Protection Analysis (LOPA)
–– Risk and criteria –– Syndicate exercises
Day 2 agenda*
–– Event tree analysis –– Syndicate exercises
–– Reliability concepts of elements and states
–– Guided exercise - development of fault trees to
assess hazards
Day 3 agenda*
–– Use and collection of reliability data –– Syndicate exercises
–– Trip system overview
Day 4 agenda*
–– Protective systems mathematics and assessment –– Failure dependency - key issues regarding
techniques dependent failure
–– Limiting factors in PFDawg - common cause –– Syndicate exercises
failures etc. –– Intro to hazard study 2 quantification exercise
Day 5 agenda*
–– Hazard study 2 syndicate exercise - applying the principles learned over the week
*ABB reserve the right to amend the course agenda.
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Advanced HAZOP for HAZOP leaders
Are you looking to continuously improve the What the course will cover?
way you conduct HAZOP studies? This course has been developed by ABB’s
experienced leaders by reflecting upon
Do you want HAZOP studies to be more those years of experience. ABB have
effective? identified both good and best practice
techniques to further enhance the
Are you interested in how best to apply the methodology and develop advanced HAZOP
HAZOP technique to an existing process techniques. Employing advanced HAZOP
and keep the HAZOP evergreen through the techniques ensures a greater depth of
re-validation process? review is achieved, links to LOPA studies are
built, good action specification is
The HAZOP methodology is a well implemented, links to alarm management
established technique used throughout and integrity management. Traditionally the
industry for hazard identification and risk HAZOP technique has been applied during
assessment. The technique was originally the detailed design stage of a project. This
developed in the 1960’s by ICI and guidance course will show how the advanced HAZOP
on its use was first published in the 1970’s technique can be applied retrospectively to
following the Flixborough disaster where an an existing process and how the HAZOP
inadequately designed modification led to a study can be re-validated and kept
large vapour cloud explosion killing 28 evergreen.
people. The technique is formally
recognised by many regulators in many Who will benefit and what will they gain?
parts of the world and details of the HAZOP The course is aimed at reflecting upon
methodology are outlined in the existing guidance and providing new
internationally recognised standard (IEC: improved guidance for experienced leaders.
61882 - Hazard and operability studies The course is also aimed at providing
{HAZOP studies} - application guide). refresher training for experienced leaders.
Note that this course builds upon ABB’s
ABB has provided training in the HAZOP existing four day hazard study leader’s
technique for more than 20 years and course. The 4 day course or suitable
trained hundreds of personnel. alternative is a precursor to the advanced
HAZOP training course.
A D VA N C E D H A ZO P F O R H A ZO P L E A D E R S 21
Agenda*
Introduction
The need for HAZOP studies and improvement - initial project, retrospective, re-validation
Planning and preparation
–– Terms of reference workshop
–– HAZOP node definition and selection
–– HAZOP node workshop
Conducting the HAZOP
–– How to fill out the HAZOP table
–– Risk ranking
Recommendations
–– How to write effective recommendations - workshop
Retrospective and re-validation HAZOPs
Human factors and the human HAZOP
–– Human HAZOP workshop
HAZOP and link to SIL determination (e.g. FTA, LOPA) studies
HAZOP nodes for complex systems such as flares , drainage and distribution systems
Report writing
HAZOP studies and the link to asset / mechanical integrity
HAZOP studies and the link to alarm management
Review of the course
*ABB reserve the right to amend the course agenda.
22 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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An engineers guide to DSEAR
Course agenda*
Coffee / tea
Lunch
Coffee / tea
Close
*ABB reserve the right to amend the course agenda.
24 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Area classification
Compliance with DSEAR is mandatory for On completion you should be able to:
any onshore operator handling dangerous
substances and PFEER for any operator of –– Understand why area classification is
fixed offshore installations. carried out
–– Understand the principles of area
What the course will cover? classification
–– Introduction to DSEAR (2002) and in –– Understand the steps in the area
particular the requirements for area classification procedure
classification and selection of equipment –– Identify the grades of release and how
to avoid ignition sources they relate to zoning
–– The flammability of gases, vapours and –– Appreciate the industry codes available
dusts and how they relate to area that can be used to establish the extent of
classification zones
A R E A C L A S S I F I C AT I O N 25
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ATEX / DSEAR for mechanical
technicians
Are your mechanical engineering teams
In-company / open course Yes / No
aware of the requirements of ATEX / DSEAR
Duration 1/2 day
compliance for the equipment installed
within your asset?
With the advent of the ATEX directives there Who will benefit and what will they gain?
are new requirements for the specification, The course will provide a clear
installation, inspection, maintenance and understanding of the best practice
repair of mechanical equipment installed in requirements for mechanical equipment
hazardous areas. ABB is working for operating in potentially flammable
operators in the process industries to atmospheres. The course has been
achieve and maintain compliance for their designed to be of benefit to mechanical
assets. Providing a practical perspective technicians and supervisory staff. It will
based on real life experience comes also provide other engineering disciplines
naturally. with an overview of the requirements for
mechanical equipment compliance.
What the course will cover?
As part of its overall Dangerous Substances Course leader
and Explosive Atmospheres Regulations Peter Hodgson is a safety specialist with
(DSEAR) compliance programme, an end over 10 years of experience in the ATEX and
user operator will be required to provide the DSEAR field, including hazardous area
facility mechanical technicians with classification, DSEAR compliance, and
awareness training in the ATEX directives mechanical equipment risk assessment, in
and the DSEAR regulations. This short many industries including oil & gas,
course is designed to give you an chemicals, paints and coatings, material
appreciation of the following: handling, pharmaceuticals and offshore.
Course agenda*
Introduction
–– ATEX Directives, DSEAR and EPS Regulations
–– General requirements and duties
–– Introduction to hazardous area classification
–– Risk assessment of existing mechanical equipment
–– Mechanical equipment certification and marking
Coffee
–– Purchasing new mechanical equipment
–– Maintenance and inspection of mechanical equipment located in hazardous areas
–– Quiz (clarification of learning)
–– Questions and discussion of mechanical equipment compliance issues
Close
*ABB reserve the right to amend the course agenda.
28 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Deep dive audits and assessments
Who will benefit and what will they gain? –– What plant records to check and things to
The course will be of benefit to personnel look out for on plant tours
who want to obtain assurance with regards –– How to write a deep dive audit and
to the controls of their MAHs using the deep assessment report
dive audit and assessment methodology. –– How to establish a deep dive audit and
The course is of benefit to personnel who assessment program into a company’s
have responsibilities under the COMAH PSM system
regulations for the control of MAHs. ABB’s
experience is that personnel with Course leader
responsibilities for PSM and integrity Graeme Laughland is a safety specialist for
management have the right skill sets and ABB and specialises in hazard identification
are well placed to conduct deep dive audits and risk assessment and PSM auditing.
and assessments. On completion of this Graeme is a chemical engineer with 30
course you will have an understanding of years’ industrial experience gained in
how to: design, operations and process safety
consultancy. In addition to consultancy
–– Conduct a deep dive audit and assignments he tutors on a range of
assessment using ABB’s proven process safety courses and has presented
techniques and methodology papers at a number of international
–– How to plan and prepare for a deep dive conferences.
audit and assessment
–– How to carry out effective interviews with
site personnel
Course agenda*
Registration and coffee
Introductions and objectives of the day
Buncefield incident
Process safety barriers - their importance and their nature re: verification
Identifying and defining barriers and exercise
Scoping the barrier verification requirements
Planning a deep dive barrier verification study
Conducting a deep dive barrier verification
Exercise scoping barrier verification requirements
Interviewing
Barrier verification as an integral part of monitoring and reviewing PSM arrangements
Path forward workshop
Course review
*ABB reserve the right to amend the course agenda.
30 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Effective alarm management
The practitioners course
Edition 3 of EEMUA 191 - Are you up to
In-company / open course Yes / Yes
speed with the latest changes and improved
Duration 3 days
guidance?
Are you confident that your alarm system is supplemented as appropriate by the good
effective? practice guidance contained in EEMUA 191
–– The alarm management lifecycle;
Do you know if your operators are burdened requirements, recommendations and
with too many alarms and how this might good practice for alarm identification,
be improved? specification, design and implementation.
Including human factors and HMI design
Could you miss key safety or environmental –– Alarm system documentation; alarm
alarms during an incident? philosophy, alarm system requirements
specification and master alarm database
Alarm systems themselves need to be –– Setting of performance targets
managed; the alarm system needs to be Managing your alarm system for
configured in a consistent manner so that continuous improvement; the role of
the operator is in a position to take the performance measurement, monitoring
most appropriate action. ABB’s practical and review. Alarm monitoring and logging
approach to alarm management takes you tools. Alarm analysis techniques
through the full alarm lifecycle covering the –– Advanced alarm management, tools and
Projects, Operations and Maintenance techniques, risk / benefit considerations
phases. As well as offering guidance for –– Drivers and benefits for prospective and
alarm specification and design, we will help retrospective alarm rationalisation
you to identify and solve problems with
existing systems such as nuisance alarms. Who will benefit and what will they gain?
While reduced legislative risk continues to This course is suitable for anybody involved
be a major driver, significant financial in the specification, design, operation and
savings can be achieved from a well maintenance of control systems or anyone
designed and maintained alarm system who has an interest in improving their
which provides operators with an effective current alarm system.
tool to deliver operational benefits
including increased up time, higher OEE, On completion you should be able to:
improved maintenance and tighter product
quality. –– Understand why your alarm system
should be managed
What the course will cover? –– Identify and evaluate the associated
–– Standards and guidance; ASM, ISA, HSE, benefits
–– NAMUR. The course is based on the –– Have a good awareness of ISA 18.2 and the
requirements of ISA 18.2, and IEC 62682, latest standard IEC 62682 requirements
EFFEC TIVE AL ARM MANAGEMENT - THE PR AC TITIONERS COURSE 31
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Electrostatic ignition hazards -
assessment and control
A practical one day training course on the
In-company / open course Yes / No
assessment and control of electrostatic
Duration 1 day
hazards in industry.
Electrostatic hazards are common in all Who will benefit and what will they gain?
sectors of the process industries during the The course will benefit delegates from all
handling and processing of flammable industry sectors handling flammable gases,
powders and liquids. Electrostatic sparks vapours or powders.
are capable of ignition of flammable
vapours, gases and powders resulting in Course leader
potential fire and explosion. On average, Graeme Ellis is a specialist safety consultant
one incident relating to static electricity providing PSM related services within the
occurs every day throughout the chemical high hazard process industry. He specialises
industry in Europe. in risk assessment for new processes and
existing plants, inherent safety, fault tree
The Dangerous Substances and Explosive analysis, consequence assessment, basis of
Atmospheres Regulations (DSEAR) came safety development, electrostatic hazards,
into force in July 2003. One important fires and explosions. Graeme is a Fellow of
requirement for compliance is to carry out the IChemE and member of the Energy
an assessment of potential ignition sources Institute Process Safety committee with
including electrostatic hazards. over 33 years experience in the process
industry in design, operational and
What the course will cover? consultancy roles.
–– How static can be generated on your plant
–– How to identify which operations on your
site are most at risk from electrostatic
hazards
–– Options for risk reduction and
management of the hazard
E L E C T R O S TAT I C I G N I T I O N H A Z A R D S - A S S E S S M E N T A N D C O N T R O L 33
Course agenda*
Registration and coffee
Introduction
Exercise: Petrol station incident
Overview of flammability hazards
Generation of electrostatic charge
Charge accumulation
Exercise: Electrostatic hazard identification
Electrostatic discharges
Ignition risk
Control measures:
–– Avoiding flammable atmospheres
–– Preventing charge generation
–– Earthing and bonding
–– Explosion protection
Exercise: Road tanker loading
Incident case studies
Close
*ABB reserve the right to amend the course agenda.
34 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Hazard study awareness
Course leader
Graeme Ellis is a specialist safety consultant Graeme is a Fellow of the IChemE and
providing PSM related services within the member of the Energy Institute Process
high hazard process industry. He specialises Safety committee with over 33 years
in risk assessment for new processes and experience in the process industry in
existing plants, inherent safety, fault tree design, operational and consultancy roles.
analysis, consequence assessment, basis of
safety development, electrostatic hazards,
fires and explosions.
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Hazard study leaders
Course leader
Stephen Beedle is a safety specialist Stephen is a senior hazard study leader and
working in the areas of risk assessment, fire has been a course tutor on the ABB hazard
and explosions, fault tree analysis, process study leaders course for several years.
hazard review and COMAH safety reports.
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Human factors and
incident investigation
This training course will equip delegates
In-company / open course Yes / No
with a toolkit to enable them to carry out
Duration 1 day
incident investigations using real case
studies from the process industries.
Session 4 - Cause tree analysis
The course focuses on human error as a The technique of cause tree analysis is
cause of incidents, how human factors can explained and a number of real examples, of
be addressed during incident investigation increasing complexity, are reviewed to
and the cause tree analysis technique point out the key facets and good practice.
What the course will cover? Session 5 - Cause tree analysis exercise
Session 1 - Incident causation A syndicate exercise, based on a real
The benefits of good incident investigation incident, is used to enable delegates to
are reviewed and the domino theory of work in teams constructing a cause tree. A
incident investigation is explained as the significant amount of time is allocated to
basis for structured cause analysis. enable delegates to explore the challenges
of using the technique. Learning from
Session 2 - Human error and incident delegates’ experiences is then shared.
investigation
The SRK human error model is developed Who will benefit and what will they gain?
from practical process industry examples This course has a high practical input of
and then an exercise is used to test tools and techniques and is aimed at those
understanding and consider the difficulties required to conduct or participate in
of addressing human error using a real incident investigations, including safety
process incident. This is followed by professionals, supervisors and plant
consideration of the way that corrective managers. The course is applicable to all
actions can be developed according to the types of industrial incident.
types of errors that are encountered.
Course leader
Session 3 - The incident investigation Robert Fogg is a safety specialist and a
process chartered chemical engineer with over 20
The basic investigation process - from years of industrial experience. Rob provides
evidence collection to corrective action PSM services including: hazard studies,
development - is reviewed, including good Safety Integrity Level (SIL) determination
practice for evidence collection and witness studies, COMAH safety reports, and PSM
interviews. support. Rob’s experience includes
management of change, project planning
and coordination, hazard management and
operator training.
H U M A N FA C TO R S A N D I N C I D E N T I N V E S T I G AT I O N 39
Agenda*
Registration
Introduction
Purpose of incident investigation
Incident causation
Human error and incident investigation
Break and syndicate exercise
The incident investigation process and cause analysis
Lunch
The cause tree analysis technique
Cause tree analysis case study
Break
Syndicate exercise based on real incident
Feedback and discussion
Review
Close
*ABB reserve the right to amend the course agenda.
40 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Human factors in the workplace
Agenda*
Introduction to human error
Competence
Task analysis
Alertness, fatigue and sleepiness
Risk assessment techniques
Design issues
Human factors in maintenance
Control rooms
Safety critical communications
Alarm systems
Human factors and behavioural safety
Human / machine interfaces
Procedures and instructions
*ABB reserve the right to amend the course agenda.
Chartered Institute
of Ergonomics
& Human Factors
RECOGNISED COURSE
42 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Human reliability analysis workshop
What the workshop will cover? Who will benefit and what will they gain?
The workshop uses real world hazard –– Those attending the ‘ABB 3 day Human
studies, process descriptions, equipment Factors in the Workplace course’, for
photos and operating procedures. The whom it will provide an ideal opportunity
delegates take these through the steps of: to apply and consolidate the knowledge
gained on the course
–– Identification and management of safety –– Previous attendees of the above course,
critical tasks or any other similar course, wishing to
–– Hierarchical task analysis develop their knowledge
–– Human reliability analysis –– Those working in the field of human
–– Consideration of performance influencing factors and human reliability, especially in
factors the process and related industries, and
–– Key competency identification wishing to gain further insights and CPD
–– Hierarchy of control review –– The workshop assumes that all delegates
–– Demonstration of ‘ALARP’ have some basic knowledge of the topics
covered as the focus is on application of
The roles of operators and managers are practical techniques to an example
played by ABB personnel allowing delegates situation
the experience of eliciting ‘real world’
operating history and practice. Specimen Workshop facilitators
answers are discussed and critiqued by the Sarah Harrison is a specialist safety
group. The process is software driven and consultant with ABB. She has worked for
PCs and software will be provided for the ABB for 6 years, in both process engineering
duration of the workshop. and process safety. Previously, she has a
wide range of technical and operations
experience in the chemical and
petrochemical industries on high-hazard
and complex plant.
Agenda*
Registration and coffee
Lunch
Competency
ALARP
—
IEC 61508 / 61511 SIL determination
—
Layer of Protection Analysis (LOPA)
Regulations today ask industry to manage Who will benefit and what will they gain?
risk by assessing the risk and taking This course will be of benefit to managers
appropriate action. and engineers who need to use LOPA as a
method of risk assessment.
LOPA is a method of risk assessment which
is used to carry out SIL determination to On completion of the course, you should be
comply with the IEC 61508 / 61511 able to:
functional safety standards, but is
increasingly used in early in design to –– Carry out a risk assessment using LOPA
assess whether further risk reduction is and appreciate the potential pitfalls
required. –– Understand its application in SIL
determination
LOPA is a tool that can be calibrated at the
time of use to allow assessment of the risk Course leader
reduction required to give a tolerable level Gaynor Woodford-Phillips is a safety
of risk. Inappropriate use and application specialist for ABB and specialises in
of LOPA can adversely affect the integrity of technical process safety which includes
layers of protection specified. Either carrying out target SIL assessments,
resulting in insufficient risk reduction or quantified risk assessments (QRA) and
over specification leading to unnecessary consequence modelling. Gaynor is a Fellow
spend in capital and operational budgets. of the Institute of Chemical Engineers with
over 25 years’ experience in project design,
What the course will cover? operations support and line management in
–– Basic risk assessment concepts and the petrochemical and chemical industries.
criteria, risk aversion, tolerability
including an exercise
–– Hazard identification, assessing
frequency and consequence
–– Identifying initiating causes and
independent layers of protection (IPLs)
–– LOPA use with several practical exercise
examples
–– The impact of humans in the equation
–– Selection and application of data within a
LOPA
–– Illustration of importance of independent
layers or protection
L AY E R O F P R OT E C T I O N A N A LY S I S ( LO PA ) 47
Agenda*
Human failure
Dependency
Close
*ABB reserve the right to amend the course agenda.
48 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Management of Change (MoC)
Course leader
Graeme Laughland is a safety specialist for In addition to consultancy assignments he
ABB and specialises in hazard identification tutors on a range of process safety courses
and risk assessment and PSM auditing. and has presented papers at a number of
Graeme is a chemical engineer with 30 international conferences.
years’ industrial experience gained in
design, operations and process safety
consultancy.
Course agenda*
Registration and coffee
Introductions and objectives of the day
MoC and the Flixborough disaster
MoC - technology / equipment
- Principles and essential features - Incident case studies
- Regulatory requirements - MoC workshop
- Key elements of site procedures - Links to Process Safety Information (PSI)
- What is a change? - Best practice approaches to MoC
PSI Workshop
- Video of MoC related incident - PHA tools and techniques
- Links to Process Hazards Analysis (PHA)
Pre-start-up safety reviews
- Principle and essential features - PSSR workshop
- Example checklists
MoC – personnel / organisation
- Principles and essential features - Incident case studies
- Regulatory requirements - Best practice approaches to MoC
- Key elements of site procedures
Workshop - What next?
*ABB reserve the right to amend the course agenda.
50 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Pressure relief
—
Pressure relief
The practitioners course
Pressure relief is an important layer of
In-company / open course Yes / Yes
protection for process plant and
Duration 3 days
equipment.
Like many technical areas there are grey –– Device sizing including:
areas within the standards and pitfalls to • Supercritical relief
catch out the unwary. This course has been • Direct integral sizing methods
designed as a follow on to the ABB pressure • Liquid none certified relief valves
relief - a proven approach course. It builds –– Pressure drop calculations
upon the themes discussed and expands • Beyond 3%
these into more complex areas of the –– Low pressure storage tanks including
subject and into areas which require • Liquid overflows
engineering judgement or as the standards • Inbreathing with condensation
put it “might not be appropriate”. The –– Discharge and disposal including
Practitioners course is designed such that • Header design
engineers have time to develop their • Venting / flaring scenarios
engineering skills doing practical pressure • KO drum sizing
problems. As this is a practitioners course it • Vibration
is recommended that delegates have been –– Case study
on the ABB pressure relief - a proven
approach course or have experience with Who will benefit and what will they gain?
pressure relief through their work. This course is aimed at engineers who wish
to develop their skills and understanding of
The course will use ABB PEL software pressure relief through guided practical
during some of the tasks. Delegates will be work.
provided with the software and licence
before the course. They can bring their own Course leader
laptop, but if this is not practicable then Chris Flower is a chemical engineering
ABB can provide a training laptop. specialist with over 15 years of process
engineering experience. Throughout his
What will course will cover? career Chris has been involved in pressure
The course will cover the following topics: relief be it, designing new systems,
reviewing existing systems or validating
–– Pressure relief philosophies systems designed by others across the
–– Pressure relief scenarios whole range of process industry sectors.
–– Calculation of relief rates including: Chris has lead the pressure relief course for
• Determination of alternative relief more than 7 years training over 100
routes delegates a year.
• Multicomponent fire
• Distillation columns
PRESSURE RELIEF - THE PR AC TITIONERS COURSE 53
Please note that this course will not be available till late 2019.
54 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
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Process Safety Management (PSM)
best practice
Process safety has hit the headlines in
In-company / open course Yes / Yes
recent years following the major explosions
Duration 5 days
and fires at BP’s Texas City refinery and the
Buncefield storage depot in the UK.
This training course is based on the PSM
The Baker panel review in the USA and the framework provided by OSHA in the USA
Health and Safety Executive’s ‘Leading from and by the HSE in the UK. It also includes
the top - avoiding major accidents’ the practical experience of ABB process
programme in the UK has amplified the safety consultants in the design and
importance of effective Process Safety operation of high hazard process plants.
Management (PSM). An essential part of
effective PSM is an integrated and What the course will cover?
comprehensive PSM system. The PSM The course consists of presentations,
system needs to include both technical and interactive case studies and practical
organisational elements as specified in the exercises. It combines an understanding of
OSHA CFR 1910 for PSM, and the UK HSE’s the theoretical requirements with practical
HSG 65 successful Health and Safety implementation.
management. The latter is used as the
framework for demonstrating that UK Who will benefit and what will they gain?
COMAH sites comply with the requirements This course is aimed at operations
of the Seveso III directive. managers, senior process engineers and
safety specialists within an organisation
Consequences responsible for leading process safety,
Major H&S Process safety monitoring the performance of PSM
consequences arrangements and implementing
improvements to achieve high levels of
Very serious Occupational safety
internal
process safety performance. The course will
incident assist delegates to:
Course leader
Graeme Laughland is a safety specialist for In addition to consultancy assignments he
ABB and specialises in hazard identification tutors on a range of process safety courses
and risk assessment and PSM auditing. and has presented papers at a number of
Graeme is a chemical engineer with 30 international conferences.
years’ industrial experience gained in
design, operations and process safety
consultancy.
Agenda*
Day 1 Introduction to PSM Achieving effective PSM
Management and leadership PSPIs
Day 2 Process safety information Process Hazard Analysis / Hazard studies
–– Chemical hazard information –– Techniques
–– Process technology information –– Inherent safety
–– Equipment design information –– Re-validation
Day 3 Operating procedures Safe work practices
Training and competence Contractors
Day 4 Mechanical integrity Pre-start-up Safety Reviews
Management of change Emergency planning and response
Day 5 Incident investigation Course review
Auditing
*ABB reserve the right to amend the agenda.
56 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
SIL awareness for control /
electrical technicians
Are your control / electrical engineering
In-company / open course Yes / Yes
teams aware of the requirements of
Duration 1/2 day
IEC 61508 / 61511 compliance for the trips
and alarms installed within your asset?
This short course is designed to give you an
With the advent of the IEC 61508 / 61511 appreciation of the following:
standards there are best practice
requirements for the specification, –– A brief introduction to the IEC 61508 /
installation, inspection, maintenance and 61511 standards and the guidance for
repair of Safety Instrumented Systems (SIS) operating, maintaining and managing SIS
installed within the workplace. ABB will help –– An introduction to risk and the concept of
you to achieve and maintain compliance for Safety Integrity Level (SIL)
your assets. Providing a practical –– An overview of designing a Safety
perspective based on real life experience Instrumented Function (SIF)
comes naturally. –– The importance of testing and
maintaining SIF
What the course will cover? –– The need for documentation and records
The course will provide you with a clear to support the operational basis of safety
understanding of the best practice
requirements for SIS operating as part of Course leader
your plant’s layers of protection. Paul Lucas is a principal safety consultant at
ABB with over 35 years’ experience of real-
Who will benefit and what will they gain? time computing and instrumented safety in
The course has been designed to be of the process chemical, oil & gas and
benefit to control / electrical technicians pharmaceutical sectors. He designs and
and supervisory staff. It will also provide delivers ABB’s training courses and
other engineering disciplines with an seminars on the practical implications for
overview of the requirements for managing end users, system integrators and
SIS. instrument technicians in the use of the
IEC61511 functional safety standard, on
As part of your overall basis of safety managing Functional Safety and detailed
management requirements, an end user design of safety instrumented functions. In
operator will be required to provide the recent years, Paul has completed a Master’s
facility control / electrical technicians with degree in Ergonomics and Human Factors
awareness training in the requirements of to gain theoretic background in support of
SIS maintenance. many years operational experience in the
assessment and analysis of Human Factors
in Safety Critical tasks, including Task
analysis and Human Error Analysis (HEA).
SIL AWARENESS FOR CONTROL / ELEC TRIC AL TECHNICIANS 57
Agenda*
Registration, coffee and bacon rolls
Introduction
Why do we need Safety Instrumented Systems (SIS)?
Functional safety standards - IEC 61508 & IEC 61511
Risk and risk reduction
Designing a safety instrumented function
Coffee
The importance of testing and maintaining safety instrumented functions
Recording, reviewing and improving
Quiz (Clarification of learning)
Questions
Close
*ABB reserve the right to amend the agenda.
58
—
Asset integrity
59
60 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Design and operation of piping
systems
This 2 day course explains why it is
In-company / open course Yes / Yes
necessary to pay attention to piping
Duration 2 days
systems at all stages throughout their life
to prevent loss of containment and maintain
a licence to operate. On completion you should be able to:
What the course will cover? –– Manage the safe operation, maintenance
The main topics relating to design and safe and commissioning of piping systems
operation of piping systems which include: –– Improve business productivity by reduced
maintenance and capital costs
–– Code compliance –– Recognise the need for, and the
–– Layout importance of, design codes and
–– Routing registration of critical piping systems
–– Flexibility analysis –– Have an awareness of the technical
–– Supporting aspects of piping that must be considered
–– Testing when designing, constructing, modifying
–– Commissioning or maintaining piping systems,
highlighting the need to control
Topics are covered by discussion, case modifications
studies of real incidents and syndicate –– Identify the modes of failure of piping
exercises. It is expected that participants systems due to inadequate design,
of this course will have gained some flexibility, supporting or routing
knowledge of the subject, either by
experience or by attendance on the Course leader
appropriate courses. Graham Harvey is an asset integrity
specialist responsible for delivery of
Who will benefit and what will they gain? integrity management studies and
This course will identify the principles and strategies, including asset life extension
methods of piping design together with the studies at on and off-shore oil and gas
considerations to be taken into account for facilities, chemical and pharmaceutical
layout and routing, testing, commissioning plants. This includes conducting due
and safe operation of piping systems. You diligence studies on high hazard processes,
will gain an increased understanding of the development of integrity management
causes of piping failures and how to resolve procedures and audit protocols. Graham
the problems that can occur. has 37 years of operational experience
gained in oil and gas, petrochemicals &
The course is beneficial to anyone who is plastics, and food processing industries,
involved in design, construction, inspection, many of which were high hazard top-tier
operation or maintenance who needs a COMAH facilities.
design appreciation or to be aware of safer
piping practices.
D E S I G N A N D O P E R AT I O N O F P I P I N G S Y S T E M S 61
—
Essentials of pressure systems
—
Mechanical integrity
Lessons from process industry incidents
According to incident data, failure of
In-company / open course Yes / No
pressure equipment is the greatest
Duration 2 days
contributor to major losses of containment
in the process industries.
Who will benefit and what will they gain?
By better understanding how plant The course is aimed at participants of all
equipment can fail, all personnel in the backgrounds who require an understanding
process industries can improve equipment of the threats to the integrity of equipment.
integrity. Whether they are involved in the This will enable them to make better
design or operational phases, managers, contributions to risk management
engineers and operators need to be aware processes throughout the asset life cycle,
of the risks of loss of containment, poor including hazard studies, management of
reliability and inadequate plant change, and operational and maintenance
performance. procedures. The course will also benefit
anyone who is involved in the operation and
What will the course cover? integrity management of ageing plant.
This two-day course uses the findings from
process industry incidents to illustrate how On completion you should be able to:
potential threats to asset integrity can arise
throughout the asset life cycle. The course –– Appreciate the basic design requirements
will cover: for pressure equipment
–– Understand the main forms of
–– Overview of design standards deterioration and best ways to manage
–– How material properties can affect them
selection of materials of construction –– Understand the key elements of an
–– Equipment design limitations integrity management system
–– Equipment failure modes –– Identify sources of good practice
–– Forms of deterioration guidance for mechanical integrity
–– Inspection options and their limitations –– Improve management of change
–– The impact of modifications to –– Identify the key issues associated with
equipment ageing plant
Course leader
Kev Senior is the Machines Functional Kev is a Chartered Engineer and Fellow of
Leader and Design Verification Engineer for the IMechE in addition to his being a
rotating equipment. He specialises in root Chartered Manager and a Fellow of the CMI.
cause analysis, fault-finding, asset health During the majority of his 30+ years
checks, life extension studies, design professional engineering career he has
verification and recommending reliability & been principally responsible for managing
maintenance improvements. the technical and logistic support of gas
turbines.
—
Mechanical legislation awareness
Course leader
Kev Senior is the Machines Functional Kev is a Chartered Engineer and Fellow of
Leader and Design Verification Engineer for the IMechE in addition to his being a
rotating equipment. He specialises in root Chartered Manager and a Fellow of the CMI.
cause analysis, fault-finding, asset health During the majority of his 30+ years
checks, life extension studies, design professional engineering career he has
verification and recommending reliability & been principally responsible for managing
maintenance improvements. the technical and logistic support of gas
turbines.
Course agenda*
Registration and coffee
Introduction
Presentation (1st module)
Coffee and tea
Presentation (1st module)
Lunch
Presentation (2nd module)
Coffee and tea
Presentation (2nd module)
Close
*ABB reserve the right to amend the course agenda.
68 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Risk Based Inspection (RBI) and
Non-Intrusive Inspection (NII)
A practical two day training course to give
In-company / open course Yes / Yes
an understanding of the RBI process and
Duration 2 days
how to implement it.
Asset integrity is key to ensuring operations The journey through this risk process is
are safe, profitable and productive. diversely knowledge based. The rigour
Maintaining integrity whilst minimising applied often reveals risks that have not
downtime leads to a difficult balance. been considered previously.
Inspection of assets provides vital
information on the condition of the asset The challenge is to use this understanding
but can include intrusive examinations of deterioration mechanisms, failure modes
involving expensive preparation of and associated risks to focus attention and
equipment and down time but giving little prioritise on critical or ‘real risks’. The
information on the remnant life of the implementation of remedial measures, in
equipment. Prescriptive practises do not these identified cases, can yield significant
take account of the risk and consequence of returns in terms of risk improvements. The
failure of specific equipment. They neither level of detail and precision explored and
focus inspection on the areas of greatest the approach can range from general to
concern nor take into account the complex and can be qualitative or
knowledge of the actual operating quantitative. The approach is governed by
conditions. risks associated with the items under study.
Risk Based Inspection (RBI) offers What will the course cover?
significant benefits over conventional –– The steps involved in a qualitative (team
inspection. As well as improved risk based) RBI study, meeting the
management, typical benefits include more requirements of API 580.
uptime and reduced costs. In the UK the –– The methodology within each step of an
Pressure System Safety Regulations 2000 RBI
(PSSR) have increased the opportunity to –– How individuals can contribute to RBIs
move from prescriptive intervals and most effectively
schemes to a RBI approach. –– The information and commitment
required
The RBI approach ensures that the optimum –– The benefits of RBI
interval and scheme of examination is
implemented, concentrating on specific
deterioration mechanisms and focusing on
the areas of greatest concern. RBI allows
operating conditions and the results from
previous examinations to be used to
optimise the inspection undertaken.
RISK B A SED INSPEC TION (RBI) 69
Who will benefit and what will they gain? Course leader
This course will appeal to asset engineers Paul Jackson is an inspection specialist and
and operators wishing to understand the has over 30 years experience of the design
RBI process, the commitment required and and inspection of pressure equipment. He is
the resultant benefit. a Fellow of the Institution of Mechanical
Engineers and Chairman of its Pressure
On completion you should be able to: Systems Group Committee.
—
Maintenance
and reliability
71
72 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Failure Modes & Effects and
Criticality Analysis (FMECA)
Today UK industry must be as efficient as
In-company / open course Yes / Yes
possible to compete in the global market
Duration 1 day
place. A key driver for this is the reliability of
the plant assets.
–– Produce generic FMEA data to apply
What will the course cover? across an equipment group e.g. pumps
The criticality analysis methodology and its –– Apply the results of both processes to the
application in prioritising equipment and generation of effective equipment
focusing reliability work. maintenance policies
Agenda*
Registration and coffee
Criticality analysis:
–– Basic principles
–– Criteria selection
–– Rating systems
–– Using the results
–– Risk prioritisation
FMEA / FMECA:
–– Basic principles
–– Structure and application
Lunch
Functions:
–– Functional analysis
–– Function tree exercise
Failure modes:
–– Potential modes of failure
–– Potential causes and effects
–– Failure mode criticality in FMECA
–– Failure modes exercise
FMECA output
–– Using the results to develop effective maintenance policies
Close
*ABB reserve the right to amend the course agenda.
74 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Introduction to reliability workshop
Who will benefit and what will they gain? Workshop facilitators
Representatives from all businesses and Martin Brown is a consultant and
organisations involved in the reliability and experienced practitioner involved in
maintenance of assets would benefit from improving maintenance, reliability and
attending this workshop. It would be of integrity management for a wide range of
particular interest to site managers; companies across the chemical, oil & gas,
maintenance and engineering managers; power and pharmaceutical industries.
plant engineers and reliability engineers;
plant / operations managers and health, Laurence Plant is a consultant with a
safety & environmental managers. The maintenance and engineering background
workshop will provide an excellent in pharmaceuticals, chemicals FMCG and
opportunity for networking with other plastics. Laurence has been involved in a
professionals who share an interest in asset wide range of reliability improvement
reliability. projects.
Agenda*
Registration and coffee
Introduction
Reliability - the basics
Criticality analysis
Coffee and networking
Loss analysis and reporting
Root Cause Analysis (RCA)
Lunch and networking
Failure Modes & Effects Analysis (FMEA)
Coffee and networking
Spares management
Key Performance Indicators (KPIs) and benchmarking
Maintenance and reliability issues - CEDAC
Closing comments
*ABB reserve the right to amend the agenda.
76 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Root Cause Analysis (RCA)
Agenda*
Registration and coffee
Introduction
Why do we want to get to the root cause?
Problem definition
How to define a problem clearly and accurately
RCA process
The ‘5 whys method
Lunch
Recording an RCA
The cause tree diagram
Finding the primary cause
How to eliminate incorrect causes
RCA group exercise
The ‘Nail bed’ problem
Close
*ABB reserve the right to amend the course agenda.
78 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Shutdown, turnaround and outage
management
Are you equipped to manage an event that
In-company / open course Yes / No
may have a significant impact on your
Duration 1 day
business’s financial performance and the
reliability and integrity of its assets?
Who will benefit and what will they gain?
There is no doubt that engineers are faced Anybody from the oil & gas, chemicals,
with ever increasing challenges when petrochemicals, power, pharmaceuticals
managing shutdowns, turnarounds and and other process industries who are
outages. They are highly complex events involved in or impacted by the execution of
with significant pressure to succeed against shutdowns, turnarounds and outages on
tight timescales, constrained budgets and their facilities.
resources and a need to achieve the highest
possible HSE standards. Without an It will be of particular interest to:
understanding of a structured approach to
shutdown management achieving the goals –– Current or potential future shutdown,
of a successful event would be virtually turnaround or outage managers
impossible. –– Project engineers and managers
–– Plant maintenance engineers and
ABB has designed a course specifically to reliability engineers
enhance the skills that you will need to –– Plant / operations managers
manage a successful shutdown. It is based –– Shutdown, turnaround or outage planners
upon ABB’s shutdown, turnaround and and coordinators
outage model of excellence and our
consultants’ extensive practical experience Course leaders
of shutdown management. Martin Brown is a consultant and
experienced practitioner involved in
What will the course will cover? improving maintenance, reliability and
The course will provide a practical approach integrity management for a wide range of
to managing a successful shutdown, companies across the chemical, oil & gas,
turnaround or outage. Over the two days power and pharmaceutical industries.
the main areas of shutdown, turnaround or
outage planning and execution will be Laurence Plant is a consultant with a
reviewed together with a number of maintenance and engineering background
interactive group exercises. A course dinner in pharmaceuticals, chemicals FMCG and
will be held on the first night to enable you plastics. Laurence has been involved in a
to network effectively with other course wide range of reliability improvement
participants. projects.
S H U T D O W N , T U R N A R O U N D A N D O U TA G E M A N A G E M E N T 79
—
Other
81
82 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Construction, Design and
Management (CDM) awareness
This half day course aims to raise awareness
In-company / open course Yes / No
and give an overview of the background,
Duration 1/2 day
objectives and requirements of the CDM
Regulations with an emphasis on the
changes to the Regulations introduced in Who will benefit and what will they gain?
2015. The course provides information on the
legal duties under current legislation for
The course provides information on the individuals and organisations involved in
legal duties under current legislation for construction activities.
individuals and organisations involved in
construction activities. On completion you should have:
Agenda*
Registration and coffee
Introduction
Background and history
2015 update - what has changed?
Duty holders
Documentation
Other provisions
Penalties and consequences
Summary
Close
*ABB reserve the right to amend the course agenda.
84 T E C H N I C A L T R A I N I N G A B B . C O M/ U K /C O N S U LT I N G / T R A I N I N G
—
Project management in the
process industries
“How much does poor project delivery cost
In-company / open course Yes / No
your business; and what would it be worth
Duration 2 days
to make a step change in performance?”
“Doing the wrong projects well is not much Who will benefit and what will they gain?
help” The training is aimed at people newly
appointed into project positions including:
Good project management needs to
address both: –– Project managers
–– Project engineers
–– How to identify and define the best –– Project participants
project to meet the business objectives
–– How to deliver that project in a safe, cost On completion you should be able to:
effective way
–– Define project objectives that align with
ABB has good experience of providing business objectives
project management training to operating –– Know the features of and see the benefits
companies in the process industry. We of a well managed project
understand the particular challenges that –– Understand how to identify and manage
are faced by companies in the chemical, oil key stakeholders
& gas and power sectors when delivering –– Understand and have practised the core
complex and potentially hazardous projects tools and techniques required as a project
in a highly regulated environment. Our participant or manager
trainers all have strong backgrounds in –– Understand the key skills required as a
projects, engineering and operations in the project participant or manager
process industry and are able to bring their
own experiences to the training courses Course leader
that we run. John Weston is an experienced project
manager and project control consultant,
What will the course will cover? with particular expertise in managing
–– A generic project process and the key multifunctional project teams and
elements of a successful project consultancy assignments in various
–– The role and skills of the project manager industry sectors.
–– Managing key interactions, stakeholders
and the project team
–– Key tools for use through the project
lifecycle - planning, scheduling, risk
management and option analysis
PROJEC T M A N AGEMENT IN THE PROCESS INDUS TRIES 85
— —
ABB Limited ABB Limited
Pavilion 9 The Shearer Building
Byland Way Earls Road
Belasis Business Park Grangemouth
Billingham Stirlingshire
Cleveland FK3 8XG
TS23 4EB United Kingdom
United Kingdom Phone: +44 (0)1324 494406
Phone: +44 (0)1642 372000 E-Mail: [email protected]
E-Mail: [email protected]
—
ABB Limited
Hareness Road
Altens Industrial Estate
All rights reserved
Aberdeen
AB12 3LE
United Kingdom
Phone: +44 (0)1224 592123
E-Mail: [email protected]
Copyright© 2018 ABB
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