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Master’s in Process Safety Engineering

Online master's programme of 1,900 hours in Process Safety Engineering, with 12 modules covering major accidents, hazardous substances and reactions, HAZOP, LOPA, safety instrumented systems, pressure relief, fires and explosions, consequence modelling, PSM elements and human factors, with an assigned technical tutor.

Duration1900 h
ModeOnline
LanguageEnglish
Start datesSet by the faculty
AwardSEIUM Institute diploma
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Learning outcomes

What you will be able to do

01

Explain the mechanisms of major process accidents.

02

Characterise the hazards of chemical substances and reactions.

03

Lead HAZOP studies in accordance with IEC 61882.

04

Apply LOPA and determine safety integrity levels.

05

Design safety instrumented and pressure relief systems.

06

Model the consequences of fires, explosions and toxic dispersion.

07

Implement and audit process safety management systems.

Profile

Who it's for

  • Process safety engineers.
  • HAZOP facilitators.
  • Functional safety engineers.
  • Consequence analysts.
  • Plant PSM managers.
  • Inspectors of Seveso establishments.
  • Engineering or science graduates looking to move into the chemical and petrochemical sector.
Standards & tools

What you'll work with

  • Directive 2012/18/EU (Seveso III, major-accident hazards)
  • IEC 61511 (functional safety in the process industry sector)
  • IEC 61882 (HAZOP studies)
  • OSHA 29 CFR 1910.119 (Process Safety Management)
  • API 520 and API 521 (pressure-relieving systems)
  • Directive 2014/34/EU (ATEX equipment)
  • API RP 754 (process safety performance indicators)
  • ANSI/ISA 18.2 (alarm management)
  • DNV Phast
  • PHA-Pro
  • exSILentia
  • ALOHA
  • Aspen HYSYS
Syllabus

12 modules · 1900 h

  1. 1.1Difference between process safety and personal safety
  2. 1.2The Bhopal, Piper Alpha and Buncefield accidents
  3. 1.3Loss of containment and its consequences
  4. 1.4Process safety management (PSM)
  5. 1.5Elements of the CCPS RBPS model
  6. 1.6OSHA 29 CFR 1910.119
  7. 1.7Seveso III Directive
  8. 1.8Cost of major accidents
  9. 1.9Historical lessons learned
  10. 1.10Case study: analysis of Buncefield
  1. 2.1Flammability and explosive limits
  2. 2.2Toxicity and AEGL values
  3. 2.3Chemical reactivity and runaway reactions
  4. 2.4Calorimetry and DSC
  5. 2.5Chemical incompatibility matrices
  6. 2.6Combustible dusts and their characterisation
  7. 2.7CLP hazardous substances
  8. 2.8Safety data sheets
  9. 2.9Inventories and Seveso thresholds
  10. 2.10Lab: thermal stability analysis with DSC
  1. 3.1Methodology and guidewords
  2. 3.2Preparation and nodes
  3. 3.3Leading sessions
  4. 3.4Recording and recommendations
  5. 3.5Procedural HAZOP
  6. 3.6Batch HAZOP
  7. 3.7IEC 61882 HAZOP studies
  8. 3.8Quality and review of HAZOP
  9. 3.9Software-assisted HAZOP
  10. 3.10Practical exercise: HAZOP of a nitration reactor
  1. 4.1LOPA scenarios
  2. 4.2Initiating events and frequencies
  3. 4.3Independent protection layers
  4. 4.4Conditional probability modifiers
  5. 4.5Tolerability criteria
  6. 4.6Calculation of the target SIL
  7. 4.7Limitations of LOPA
  8. 4.8Integration with HAZOP
  9. 4.9Documentation and audit
  10. 4.10Practical exercise: LOPA of overpressure in a separator
  1. 5.1IEC 61511 lifecycle
  2. 5.2Safety requirements specification (SRS)
  3. 5.3Architectures and fault tolerance
  4. 5.4PFD calculation
  5. 5.5Proof testing and diagnostic coverage
  6. 5.6Bypass management
  7. 5.7Design of safety valves
  8. 5.8Alarms and operator response
  9. 5.9Functional safety and cybersecurity
  10. 5.10Lab: PFD calculation with exSILentia
  1. 6.1API 520 relief valve sizing
  2. 6.2API 521 relief scenarios
  3. 6.3Rupture discs
  4. 6.4Flares and disposal systems
  5. 6.5Reaction venting
  6. 6.6Pressure vessels and Directive 2014/68/EU
  7. 6.7Mechanical integrity programmes
  8. 6.8Corrosion and damage mechanisms
  9. 6.9API 580 risk-based inspection
  10. 6.10Practical exercise: sizing a safety valve
  1. 7.1Pool fire and jet fire models
  2. 7.2BLEVEs and fireballs
  3. 7.3Vapour cloud explosions
  4. 7.4Dust explosions
  5. 7.5Explosive atmospheres and hazardous area classification
  6. 7.6ATEX Directives 2014/34/EU and 1999/92/EC
  7. 7.7Passive fire protection
  8. 7.8Gas and flame detection systems
  9. 7.9Active protection and water systems
  10. 7.10Case study: ATEX hazardous area classification
  1. 8.1Release sources
  2. 8.2Dense gas dispersion
  3. 8.3Gaussian plume models
  4. 8.4Thermal radiation and overpressure
  5. 8.5Vulnerability of people and equipment
  6. 8.6Domino effects between installations
  7. 8.7Consequence software
  8. 8.8Model validation
  9. 8.9Use in emergency planning
  10. 8.10Lab: chlorine dispersion with ALOHA
  1. 9.1Process safety information
  2. 9.2Operating procedures and safe operating limits
  3. 9.3Management of change (MOC)
  4. 9.4Pre-startup safety review
  5. 9.5Asset integrity
  6. 9.6Competence of process personnel
  7. 9.7Contractors in process operations
  8. 9.8Permits to work in process units
  9. 9.9Incident investigation
  10. 9.10Workshop: management of change procedure
  1. 10.1Control room design
  2. 10.2ISA 18.2 alarm management
  3. 10.3Procedures and human error
  4. 10.4Operator situation awareness
  5. 10.5Fatigue in process operations
  6. 10.6Communication at shift handover
  7. 10.7Operator competence
  8. 10.8Process simulators
  9. 10.9Process safety culture
  10. 10.10Case study: alarm rationalisation
  1. 11.1API RP 754 Tiers 1 to 4
  2. 11.2Barrier indicators
  3. 11.3PSM audits
  4. 11.4Seveso safety report
  5. 11.5Seveso inspections by the competent authority
  6. 11.6Process safety benchmarking
  7. 11.7Management review of PSM
  8. 11.8Improvement plans
  9. 11.9Communication with the community
  10. 11.10Practical exercise: audit of a PSM element
  1. 12.1Selected process facility
  2. 12.2Gathering process information
  3. 12.3HAZOP of a unit
  4. 12.4LOPA and SIL determination
  5. 12.5Consequence modelling
  6. 12.6Relief and containment analysis
  7. 12.7PSM management plan
  8. 12.8Recommendations and prioritisation
  9. 12.9Master's Thesis report
  10. 12.10Master's Thesis: defence before a panel
Methodology, software & labs

How you'll learn

100% online learning on the SEIUM campus, with downloadable materials, recorded classes and an assigned technical tutor. No fixed timetables: you progress at your own pace within each intake, so it fits around your job.

Each module combines theory, guided reading of the original standard and applied exercises. The working software is DNV Phast, PHA-Pro, exSILentia, ALOHA and Aspen HYSYS, in free, academic or evaluation versions. Testing is studied through real procedures: HAZOP and LOPA studies of process units, consequence modelling of releases and audits of PSM elements. Assessment is continuous for each module, plus the final Master's Thesis.

Standards covered: Directive 2012/18/EU (Seveso III), IEC 61511, IEC 61882, OSHA 29 CFR 1910.119, API 520 and API 521, Directive 2014/34/EU (ATEX), API RP 754, ANSI/ISA 18.2.

Assigned technical tutor:every module ends with a deliverable that your tutor marks individually.
Standards-based learning:guided reading of Directive 2012/18/EU (Seveso III), IEC 61511 and IEC 61882 applied to real cases, not as a theoretical annex.
Industry software:DNV Phast, PHA-Pro, exSILentia, ALOHA and Aspen HYSYS, in free, academic or evaluation versions.
Master's Thesis with defence:a complete process safety study of a process unit, from HAZOP and LOPA to consequence modelling and a PSM plan, defended before a panel.
Flexible format:100% online, no fixed timetables, compatible with full-time work.
Capstone project

Build it end to end

Your final project follows the real engineering workflow, step by step, reviewed by your tutor.

Process information
Select a process facility and gather its process safety information.
HAZOP study
Carry out a HAZOP of one unit of the facility.
LOPA and SIL
Apply LOPA and determine the required SIL for the critical scenarios.
Consequences and relief
Model consequences and analyse relief and containment, then draft a PSM plan.
Master's Thesis
Present prioritised recommendations in your Master's Thesis, defended before a panel.
Career opportunities

Where this takes you

Process safety engineerHAZOP facilitatorFunctional safety engineerConsequence analystPlant PSM managerSeveso establishment inspector
Admissions & scholarships

Requirements

  • University degree in engineering, science or architecture, or equivalent demonstrable professional experience.
  • Internet connection and a computer capable of running the programme's software.
  • English sufficient to read technical standards.

Ready to start?

Send your application today. Our admissions team replies within 72 hours with your study plan and funding options.

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FAQ

Frequently asked questions

The programme totals 1,900 hours over 12–14 months. You set your own pace within each intake, and your tutor helps you plan the workload around your job.

You work with DNV Phast, PHA-Pro, exSILentia, ALOHA and Aspen HYSYS, using free, academic or evaluation versions. Your tutor indicates the free alternative wherever one exists.

A SEIUM Institute diploma, awarded on passing the continuous assessment and the Master's Thesis. It is SEIUM's own qualification, not an official state degree; its recognition depends on the programme completed and the regulations of each country.

Yes. Modules passed in a course or postgraduate diploma in the same area are recognised in the higher programme. Ask about the recognition policy when you enrol.

A university degree in engineering, science or architecture (or equivalent professional experience), a computer able to run the programme's software and English sufficient to read technical standards.

Start dates are set by SEIUM's faculty for each intake. Our admissions team will confirm the next available date when you apply.

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