ThinkTank Engineering is a technical training and competency development provider specialising in Process Safety Management (PSM), risk engineering, and operational discipline for high-hazard industries, including mining, minerals processing, oil & gas, and chemical manufacturing. We design and deliver instructor-led courses that build the capability of engineers, operators, supervisors, and leaders to identify hazards, manage risk, and sustain safe, reliable operations.
Our curriculum spans awareness-level courses that build a shared understanding of process safety fundamentals, through to specialised, facilitator-grade programmes that develop the technical experts and risk facilitators an organisation depends on.
These courses build a shared, organisation-wide understanding of process safety and risk management principles. They are designed for broad participation across engineering, operations, maintenance, and HSE functions. Specialised courses develop deep technical and facilitation capability for individuals who lead, facilitate, or audit critical risk-management processes.
Our general approach:
Durations below reflect our standard course design. Each course can be customised in length and scope to suit your organisation's specific requirements.
Every course in our portfolio is led by a topic-specific subject matter expert with 15+ years of hands-on experience in Process Safety Management. From Process Hazard Analysis and Mechanical Integrity to Permit to Work, Incident Investigation, and Human Factors, each facilitator brings deep practitioner-level knowledge of their subject, gained through years of direct application in high-hazard operating environments. This ensures every session moves beyond theory, giving participants access to real operational insight, seasoned judgement, and practical guidance they can apply directly to their own workplace.
Process Safety Information (PSI) - 1 day
To provide participants with a comprehensive understanding of Process Safety Information (PSI) and how it underpins effective process safety management (PSM) systems.
Introduction to Process Hazard Analysis and Risk Management Processes - 2 days
This course introduces the essential tools and frameworks used in Process Hazard Analysis (PHA) and risk management.
Standard Operating Procedures (SOP) - 2 day
This course provides practical guidance on designing, writing, reviewing, and using Standard Operating Procedures (SOPs) to ensure safety, consistency, compliance, and operational discipline.
Safe Working Practices/Permit to Work for Leaders - 2 day
This course empowers leaders to take ownership of Permit to Work (PTW) systems and high-risk activity control.
Incident Investigation for Leaders - 2 days
This course equips leaders with the knowledge and skills to lead or oversee effective incident investigations.
PSM Competency Development - 1 day
This intensive course is designed to strengthen individual and team competencies in Process Safety Management (PSM) by providing foundational knowledge, role clarity, and practical understanding of PSM systems.
Mechanical Integrity for Leaders - 1 day
This course develops leadership capability in understanding, overseeing, and driving effective Mechanical Integrity (MI) programs.
MOC for Leaders - 2 days
This course empowers leaders to manage and control change in a way that protects people, assets, and the environment.
PSSR - 2 days
This course equips participants with the knowledge and tools to effectively plan, lead, and verify Pre-Startup Safety Reviews (PSSR) as a critical final step before the introduction of hazardous energy or materials.
Emergency Response - 1 day
This training aims to develop foundational competence in emergency response planning and execution across high-risk operations.
Contractor Safety Management - 2 day
This course builds leadership capability and system discipline for managing contractor safety across the full lifecycle — from selection and onboarding to field execution and performance evaluation.
PSM Auditing -1 day
This course develops auditing competence for Process Safety Management (PSM) systems.
PS Key Performance Indicators - 1 day
This course provides participants with the knowledge and tools to develop, interpret, and apply Process Safety KPIs.
PHA - HAZOP Facilitator - 3 days
This course builds advanced technical and leadership capabilities required to successfully facilitate HAZOP (Hazard and Operability) studies.
PHA - LOPA Facilitator - 3 days
This course builds deep technical and facilitation capability for leading Layer of Protection Analysis (LOPA) sessions.
PHA -BOWTIE Facilitator - 3 days
This course develops the technical and facilitation skills required to build, lead, and document Bowtie risk assessments that meet global good practice standards (ICMM, CCPS, ISO 31000).
PHA - HAZID Facilitator - 2 days
Equip participants with the methodology, tools, and leadership skills needed to successfully plan, facilitate, and document HAZID workshops in a structured and repeatable manner, ensuring risks are identified early and managed proactively.
Introduction to Alarm Management - 2 days
To build awareness and understanding of alarm system design, performance, rationalisation, and monitoring.
Mechanical Integrity and Quality Assurance (MIQA) - 5 days
To equip participants with the knowledge, tools, and practices needed to build, manage, and continuously improve a comprehensive Mechanical Integrity and Quality Assurance (MIQA) system.
MOC for Specialists/Owners - 4 days
To build user-level capability to identify and manage change safely and effectively.
PTW for issuers and receivers - 3 days
To develop strong competence in safely planning, authorizing, executing, and closing work permits in accordance with best practices and company procedures, while managing associated risks and maintaining operational control.
Emergency Response for ERP Participants - 3 days
To ensure that all ERP participants understand their role within the emergency structure, are familiar with the site ERP procedures, and are capable of responding to and supporting site-level emergencies with competence and confidence.
Contractor Safety Management - 4 days
To equip users with the tools, responsibilities, and critical thinking skills needed to manage contractor safety risk effectively throughout the full contract lifecycle—from pre-qualification to on-site execution and post-job evaluation.
PSM Auditing for Auditors - 2 days
To equip auditors with the knowledge, methodology, and tools needed to perform effective and insightful PSM audits, ensuring both regulatory compliance and genuine system performance.
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