Applied Chemical Handling, Laboratory & Process Safety Training Course

Chemicals are used far beyond refineries and large plants. Hospital and university laboratories, water utilities, mines, food processors, paint and plastics factories and agro-dealers all store and handle substances that are flammable, corrosive, toxic or reactive. When hazard information is incomplete, storage is improvised or a process change goes ahead without review, the consequences range from chronic worker exposure to fires, explosions and environmental releases that halt operations and damage community trust.

The Applied Chemical Handling, Laboratory & Process Safety Training Course moves from the bench to the plant. It opens with hazard classification under GHS, safety data sheets, labelling and occupational exposure limits, then turns to safe storage, segregation of incompatibles, transfer and dispensing, and waste disposal. Laboratory practice is covered in detail, including fume cupboard performance, compressed gases, cryogens, glassware and emergency showers. The later days introduce process safety: hazard identification methods, HAZOP and what-if studies, bow-tie diagrams, layers of protection, safety-critical equipment, isolation procedures, change control and incident investigation.

Teaching is applied throughout. Participants assess real safety data sheets, plan a chemical store layout, rehearse a spill response with a full kit and take part in a HAZOP session on a sample piping and instrumentation diagram. Each delegate leaves with a set of completed assessments and a site improvement plan.

On completing the programme, participants will be able to:

• Classify chemical hazards using GHS criteria and interpret every section of a safety data sheet.
• Assess exposure risks against occupational exposure limits and select controls using the hierarchy of controls.
• Design chemical storage that segregates incompatible substances and meets fire and ventilation requirements.
• Apply safe laboratory practice for fume cupboards, compressed gases, cryogens and hazardous waste.
• Plan and lead an effective response to chemical spills, splashes and releases.
• Conduct HAZOP, what-if and bow-tie reviews on laboratory and process systems.
• Implement permit-to-work and management of change controls for process modifications.
• Investigate chemical incidents and near misses to identify root causes and corrective actions.

Anyone who stores, uses or oversees hazardous substances at the bench or on the plant will benefit, particularly:

• Laboratory managers, analysts and technicians in industrial, academic and medical settings
• Chemical, process and production engineers
• HSE managers, safety officers and occupational hygienists
• Production supervisors and plant operators in manufacturing, mining and food processing
• Water and wastewater treatment plant staff
• Quality and compliance staff in pharmaceutical, agrochemical and paint companies
• Warehouse, stores and logistics supervisors handling dangerous goods
• Emergency response team leaders and fire wardens
• Inspectors responsible for workplace chemical safety

By the final session each participant will hold:

• A completed chemical risk assessment for a substance used in their own workplace.
• A storage segregation chart and store layout sketch that can be checked against site conditions.
• A safety data sheet review checklist for receiving and approving new chemicals.
• A spill response procedure matched to the kit and chemicals on their site.
• A HAZOP worksheet of deviations, causes, consequences and safeguards from a live session.
• A bow-tie diagram for one major chemical hazard showing preventive and mitigating barriers.
• A management of change form and review route ready for adaptation.
• A prioritised site improvement plan with owners and target dates.

Participants spend much of the week handling the documents, equipment and decisions they meet at work. Methods include:

• Safety data sheet and label analysis using real supplier documents
• Practical demonstrations of PPE selection, fume cupboard checks and spill kit use
• A facilitated HAZOP session run on a sample piping and instrumentation diagram
• Incident case studies from laboratories, warehouses and chemical plants
• Store layout and segregation design exercises in small groups
• Site improvement planning with peer and facilitator feedback

A CPD-accredited Certificate of Completion issued by Vision Reach Global Consultancy is awarded to each participant who attends the full programme and completes the risk assessment, storage design, spill drill and HAZOP exercises.

The completed worksheets also make a practical record for safety committees, supervisors and annual competence reviews.