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Quest Training

Process Safety Performance Indicators (API RP 754) Training Course

Covers measuring process safety performance under API RP 754, classifying process safety events and using indicator data to cut the risk of major incidents.

PSRM · Process Safety & Operational Risk ManagementAll Levels#2770ClassroomEnglish , Arabic
Duration
5 Days
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Free substitution at any time · 30+ days' notice: full refund minus 10%. Cancellation policy

Sectors:Health, Safety, Environment & SustainabilityCategories:Process Safety & Operational Risk Management

Course Overview

This course provides practical knowledge of process safety performance indicators in accordance with API Recommended Practice 754 (API RP 754). It focuses on measuring process safety performance, classifying process safety events, monitoring the effectiveness of preventive and mitigative controls, and using performance data to reduce the likelihood of major process incidents. Participants examine the four-tier process safety performance indicator framework, including lagging and leading indicators, event classification criteria, data collection methods, reporting requirements, and performance evaluation. The programme also addresses the relationship between process safety indicators, barrier management, incident investigation, risk assessment, and continuous improvement. Practical exercises enable participants to classify process safety events, calculate relevant performance indicators, analyze trends, identify weaknesses in safety controls, and develop reporting dashboards that support operational decisions and process safety improvement initiatives.

Learning Objectives

  • Explain the purpose, structure, and application of API RP 754.
  • Distinguish between leading and lagging process safety performance indicators.
  • Interpret the four-tier framework used to measure process safety performance.
  • Apply event classification criteria to process safety incidents and loss-of-containment events.
  • Identify the data required to calculate and report process safety indicators.
  • Calculate relevant process safety performance metrics using consistent definitions and reporting boundaries.
  • Evaluate the effectiveness of process safety barriers and risk controls.
  • Analyze indicator trends to identify recurring events, weaknesses, and emerging risks.
  • Establish procedures for collecting, validating, classifying, and reporting process safety data.
  • Develop process safety performance dashboards and management reports.
  • Integrate indicator results with incident investigation, risk management, and corrective action processes.
  • Establish improvement plans based on process safety performance findings.

Who Should Attend

This course is designed for process safety engineers, HSE managers, operations managers, production engineers, reliability and maintenance professionals, incident investigators, risk management specialists, performance analysts, and personnel responsible for monitoring or reporting process safety performance. It is particularly relevant to oil and gas companies, refineries, petrochemical plants, chemical manufacturing facilities, gas processing operations, offshore installations, and other process industries where effective performance measurement is essential to preventing major accidents, improving operational reliability, and strengthening process safety management.

Learning Outcomes

  • Interpret API RP 754 principles and apply relevant indicator definitions to organizational activities.
  • Explain the purpose and application of the four-tier process safety performance framework.
  • Classify process safety events according to applicable reporting criteria.
  • Distinguish process safety events from occupational safety incidents and other operational events.
  • Identify suitable leading and lagging indicators for process safety monitoring.
  • Calculate and interpret relevant event rates and performance measures using appropriate reporting data.
  • Establish consistent data collection, validation, classification, and reporting processes.
  • Evaluate the performance of critical safeguards and process safety management systems.
  • Identify trends, recurring event patterns, and weaknesses in operational controls.
  • Develop dashboards and reports that communicate process safety performance effectively.
  • Use indicator findings to support incident investigation and corrective action prioritization.
  • Prepare a structured process safety performance improvement plan.

Course Outline

Day 1

API RP 754 Fundamentals and Process Safety Performance Measurement

  • Purpose, scope, and industry applications of API RP 754.
  • Process safety performance measurement and its role in preventing major incidents.
  • Relationship between process safety management, operational risk, and performance monitoring.
  • Overview of the four-tier process safety performance indicator framework.
  • Differences between leading indicators and lagging indicators.
  • Relationship between process safety events, loss of primary containment, and major accident hazards.
  • Indicator definitions, reporting boundaries, and consistency of measurement.
  • Responsibilities for process safety data collection, review, and reporting.
  • Relationship between API RP 754 and other process safety management practices.
  • Practical Exercise: Review selected process safety scenarios and identify suitable indicators for monitoring performance and control effectiveness.
Day 2

Tier 1 and Tier 2 Process Safety Events and Classification

  • Purpose and significance of Tier 1 and Tier 2 process safety indicators.
  • Understanding loss of primary containment and applicable event classification principles.
  • Reviewing threshold criteria for reportable process safety events.
  • Classifying events according to relevant consequence and release criteria.
  • Understanding the role of hazardous substances, release characteristics, and event circumstances.
  • Evaluating reporting boundaries and determining whether events meet applicable criteria.
  • Distinguishing reportable process safety events from occupational injuries and routine operational deviations.
  • Data requirements for Tier 1 and Tier 2 performance measurement.
  • Common classification errors and methods for improving reporting consistency.
  • Documenting event information and maintaining traceable classification records.
  • Practical Exercise: Classify a series of process safety event scenarios and determine the appropriate reporting category using the applicable API RP 754 criteria.
Day 3

Tier 3 and Tier 4 Indicators and Leading Performance Measurement

  • Purpose and application of Tier 3 and Tier 4 indicators.
  • Monitoring process safety challenges, demands on safeguards, and operational control weaknesses.
  • Developing leading indicators for process safety management activities.
  • Monitoring maintenance and testing of safety-critical equipment.
  • Evaluating overdue inspections, process safety action items, and management of change activities.
  • Assessing operating discipline, procedure compliance, and process safety training.
  • Monitoring mechanical integrity and the condition of critical safeguards.
  • Selecting indicators that provide meaningful information about risk control effectiveness.
  • Establishing data sources, measurement frequency, responsibilities, and performance thresholds.
  • Aligning leading indicators with organizational risk priorities and process safety objectives.
  • Practical Exercise: Develop a set of leading and lagging indicators for a selected process facility, including definitions, data sources, reporting frequency, and performance targets.
Day 4

Data Collection, Performance Analysis, and Reporting

  • Establishing consistent processes for collecting process safety event data.
  • Validating data quality, completeness, accuracy, and classification.
  • Calculating relevant event counts, rates, and performance measures.
  • Selecting appropriate reporting periods and denominators.
  • Analyzing trends, recurring events, and deviations from performance targets.
  • Identifying patterns that may indicate deteriorating safeguards or increasing process risk.
  • Developing process safety performance dashboards and management reports.
  • Communicating indicator results to operational teams and senior management.
  • Integrating performance analysis with incident investigation and root cause analysis.
  • Establishing data governance, reporting responsibilities, and review procedures.
  • Practical Exercise: Analyze a sample process safety dataset, calculate selected indicators, identify performance trends, and prepare a management report highlighting key risks and improvement priorities.
Day 5

Performance Improvement, Governance, and Practical Implementation

  • Integrating API RP 754 indicators into process safety management systems.
  • Establishing indicator ownership, accountability, and reporting arrangements.
  • Defining performance targets and escalation criteria based on organizational risk priorities.
  • Linking indicators to risk assessments, barrier management, and mechanical integrity programmes.
  • Prioritizing corrective actions based on event patterns and control weaknesses.
  • Evaluating the effectiveness of improvement initiatives through performance monitoring.
  • Using indicator results to support management review and operational decision-making.
  • Establishing processes for reviewing and updating indicator definitions and reporting procedures.
  • Developing a process safety performance monitoring framework.
  • Preparing an implementation roadmap with responsibilities, milestones, and review arrangements.
  • Final Workshop: Develop a process safety performance measurement and reporting plan aligned with API RP 754, covering indicator selection, event classification, data collection, performance calculations, reporting dashboards, accountability, and improvement actions.

Upcoming Dates

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Hamburg · 19 – 23 Apr 2027 · Classroom

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