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Process Safety Plan
Posted: 18 Nov 2025, 18:02
by ivani1
We are building in an improvement plan on process safety.
Suggest how that should be shaped up for a petrochemical site.
Re: Process Safety Plan
Posted: 23 Nov 2025, 07:38
by jeem
Looks like there has been some need of that.
And if that is true then I would recommend to start with the triggers like audit findings, repeated issues, and other identified areas where the process safety performance has already been suffering.
In our case, we perform audits on yearly basis and rarely make a separate/standalone process safety improvement plan but was discussing with one of my HSE colleague who appreciated this idea. Means the point is that you perform audits and then what. Fine, you track actions, and complete them also. That's right but how you compare if the identified findings are getting repeated. A system trigger may tell you that but we thought to have an improvement plan for the past year is a good idea.
We are lacking behind on our change management. Identified cases where maintenance jobs, replacements especially were made (not like to like) only after an outside OEM recommendation. Can be done but not without registering a change. I believe that is one area for us to make a plan on.
Re: Process Safety Plan
Posted: 25 Nov 2025, 16:12
by tuan
We came up with an initiative to have Scenario Analysis focusing on chemical spills, fires, explosions, and equipment failures.
Means that would not necessarily be formal incident investigation but something apart from that process.
Scenario Analysis is performed in the form of a workshop involving those part of the incident and others to come and think with them. This would be recorded graphically on swiss cheese model to identify the failing barriers. Also this connects the defined Tier-4 indicators defined and monitored at site to identify which one was reported weak in the previous months.
Consider to have such Scenario Analysis in your process safety plan.
Re: Process Safety Plan
Posted: 22 Dec 2025, 07:40
by ivani1
tuan,
I liked the idea of having a Scenario Analysis as one of the process safety plan for next year.
Something from where all can learn & apply, if we document that in a nice way.
tuan wrote: 25 Nov 2025, 16:12
We came up with an initiative to have Scenario Analysis focusing on chemical spills, fires, explosions, and equipment failures.
Means that would not necessarily be formal incident investigation but something apart from that process.
Scenario Analysis is performed in the form of a workshop involving those part of the incident and others to come and think with them. This would be recorded graphically on swiss cheese model to identify the failing barriers. Also this connects the defined Tier-4 indicators defined and monitored at site to identify which one was reported weak in the previous months.
Consider to have such Scenario Analysis in your process safety plan.
Re: Process Safety Plan
Posted: 22 Dec 2025, 07:54
by ivani1
That is a real good idea to start with jeem.
We have been pulling out all sort of data where we are underperforming or performing just at par.
"if the identified findings are getting repeated", yes, this can be applied as a check for the last years.
Suggest me a good name we can have initiative on this.
I can call this, "Actions Effectiveness Check".
jeem wrote: 23 Nov 2025, 07:38
Looks like there has been some need of that.
And if that is true then I would recommend to start with the triggers like audit findings, repeated issues, and other identified areas where the process safety performance has already been suffering.
In our case, we perform audits on yearly basis and rarely make a separate/standalone process safety improvement plan but was discussing with one of my HSE colleague who appreciated this idea. Means the point is that you perform audits and then what. Fine, you track actions, and complete them also. That's right but how you compare if the identified findings are getting repeated. A system trigger may tell you that but we thought to have an improvement plan for the past year is a good idea.
We are lacking behind on our change management. Identified cases where maintenance jobs, replacements especially were made (not like to like) only after an outside OEM recommendation. Can be done but not without registering a change. I believe that is one area for us to make a plan on.
Re: Process Safety Plan
Posted: 14 Jan 2026, 11:02
by tuan
Do that, and add as the site best practices.
Your auditors would surely be appreciating if not done before.
ivani1 wrote: 22 Dec 2025, 07:40
tuan,
I liked the idea of having a Scenario Analysis as one of the process safety plan for next year.
Something from where all can learn & apply, if we document that in a nice way.
tuan wrote: 25 Nov 2025, 16:12
We came up with an initiative to have Scenario Analysis focusing on chemical spills, fires, explosions, and equipment failures.
Means that would not necessarily be formal incident investigation but something apart from that process.
Scenario Analysis is performed in the form of a workshop involving those part of the incident and others to come and think with them. This would be recorded graphically on swiss cheese model to identify the failing barriers. Also this connects the defined Tier-4 indicators defined and monitored at site to identify which one was reported weak in the previous months.
Consider to have such Scenario Analysis in your process safety plan.