Process Safety Cards

Process Safety Cards have a simple goal – to improve the awareness of a broad range of personnel to potential major accident scenarios and increase their vigilance to such events & their potential causes so they can be promptly addressed.

We do that with memorable images representing typical events – delivering knowledge literally into the hands of those who might contribute to and/or be affected by Process Safety Incidents.

With an ageing workforce and increased outsourcing of maintenance and operations activities, it is vital that time and knowledge poor stakeholders (who typically fall outside corporate process safety training strategies) are engaged and equipped to ensure they play their part in sustaining the integrity of assets.

Cards help build and sustain the following familiar PSM elements:

Commitment & Culture
Workforce Involvement
Stakeholder Engagement
Process Knowledge
Contractor Management
Cards ready for frontline deployment

Users or ‘Players’ are encouraged & helped to learn & apply the principles using this simple mnemonic:

  • REMEMBER Events
  • RECOGNISE Threats
  • RESPECT Barriers
  • REPORT Concerns

Thereafter, there is an obligation on the duty-holder to:

  • RESPOND to Feedback
  • RECOVER Protection

Visualization is used to get and keep the workforce onboard with the process safety mission by challenging them with these simple questions:

  1. Do you UNDERSTAND what can wrong i.e. HAZARDS?
  2. Do you KNOW what the systems are to prevent this from happening i.e. BARRIERS?

It is anticipated that, not only will site personnel benefit from these cards, 3rd parties e.g. contractors, visitors or others who may fall outside company initiatives or training can become better informed on the hazards, threats & controls that they may be involved with or impacted by.

In crude terms, this encourages everyone to:

Know Your Enemy


Remember Hazards are not the enemy – they are part of normal business with the potential to cause harm e.g. tiger or gorilla in a cage.


A pack of cards has 52 scenarios which are divided into appropriate ‘suits’ for example, LoC cards:


Containment is lost via an open route to atmosphere
External impact
Failure beyond design conditions/envelope (over-stress)
Failure within conditions/envelope (under-strength)

These provide simple visual prompts to help “players” remember that the event (Loss of Containment) is an ever-present concern:

Although the cards are designed to be intuitive, they are annotated with Event types which can be supplied in different languages or alternative terminologies.


Scenario summaries are presented as separate pages with one Event on each sheet. They include typical (suggested) Causes (Threats) and Controls (Barriers) and visual representations of the scenarios in bowtie format, for example:

Visualisation aims to help ‘Players’ recognise Threats and respect Barriers e.g. ensure their actions or inactions do not disable, degrade or delete prevention measures associated with each event.

Details of scenario components are provided on the Bowties page.


It is vital that, if the objective is to increase awareness & vigilance, appropriate resources are available to respond to questions or comments from card “players” i.e. they must be encouraged to report concerns e.g. barrier deficiencies or absence, otherwise there is limited opportunity for improvement.

In extreme cases, operations may need to be suspended, or in less urgent situations; planned corrective & preventive action may be required to recover protection or risk reduction measures to their intended presence and performance.

Cards & summaries should therefore not be deployed without adequate process safety knowledge and means to act upon feedback & challenges.

It is anticipated that these cards & summaries will reflect existing policies, procedures, principles, and practices, however if these do not exist; support to develop and deploy these is available from Process Safety Integrity and its associates.

Suggested uses and feedback is provided on the Ideas page.

We invite Users to share their experiences with the Cards & Summaries so that others may be inspired to use these tools in novel & productive ways – this is available on the Feedback page.


This simple approach to ‘microlearning’ has several potential formats, including (but not limited to):

Loss of Containment
Ignition Sources
Human Factors
Process Safety Management
Occupational Safety

Alternatively a deck based on Chemical Hazards and Safety Data Sheets (SDS) is available:

Top Trump style SDS


The following options are available:

  • Languages
  • Event images
  • Branding & Logos
  • Scenarios & Bowties
  • User Guides

Cards and Summaries are available separately and the native bowtie files (BowTieXP) are also available for Users to develop themselves.

Customised card boxes

For more information on options & pricing, please contact us.