Give us a brief on your current process safety program at Saudi Petrochemical.
It is based mostly on Sabic EHSS corporate program called SHEMS (Safety, Health, Environment , which in turn is based on OSHA PSM. Sadaf uses a site-customised version of this Sabic corporate EHS-MS which consists of 16 main categories of in total 75 elements. Much learning was taken from Shell as JV partner throughout the years based its Technical consultancy organisation expertise and also by benchmarking with its manufacturing sites to enhance our PS related practices, procedures and systems (MOC, residual risk mitigation and approval, LoTo, permit to work, etc.).
What are the changes that need to be brought in the organization and governance structure in order to implement an effective process safety program?
Leadership support and commitment is required all the way from top president to the management layer which controls the resources. Steer and governance should be provided to the process safety program by a combination of general managers (technical and operations) with selected senior managers through a committee forum with at least monthly engagement.
What are the challenges faced while training the employees on process safety?
To find the appropriate technical based courses that go beyond management level awareness. Technical process safety is enhanced through Shell e.g. (TSE-101 Safety in Process Design, HEMP-101 barrier thinking and LOPA) as well as with Sabic Learning (e.g. PHA Leader, Risk Assessment training, RIS) and others like Dupont and ABS. In addition several in-house courses are provided by Sadaf-to-Sadaf staff on Hazard recognition, Risk assessment, Barrier thinking, ALARP, etc. Most of the Process Safety engineers training takes place through on the job assignments and collaboration with industry consultants on studies and initiatives.
What are the impacts of the currently implemented process safety program on the operations of your company?
Our Reliability has improved as there is more focus on integrity, operations have improved their situational awareness and monitoring. This had led to less spills and leaks and a reduced number of unplanned shutdowns. A safe plant is a more reliable plant, and a reliable plant is a safer plant. Of course a reliable plant is a more profitable plant due to less production loss and less maintenance cost.