Winning Beginnings: Embedding Process Safety Management in Capital Projects

Abstract

Abstract Description Embedding Process Safety Management (PSM) in a capital project system is critical in helping to achieve a safe start up and is the foundation for assuring safe operations throughout the life of the process. Application Today's PSM system, practiced by most companies, is Deming-based and specifically a plan"do-check-act system that strives for continuous improvements. The capital project process is very different, with specific starting and ending points that are driven by cost and time. The result is that all required tasks for each PSM element are also time-driven, with the objective of having a full PSM program in place at the time of start-up. Additionally, capital projects must achieve designs that meet the balance of competing demands. This paper explores some of these issues that are critical to achieving on-time start-up, design operating rates, and safe operation with optimum investment and life cycle cost. The session delivers: A description of how our organisation implements PSM in capital projects, and how we manage operating risks in these projects, achieving a balance between process equipment design, instrumented control systems, and safety instrumented systems. A discussion of how to manage the critical integration of Employee Safety, Process Safety, Capital Effectiveness, and Asset Productivity. Results, Observations, Conclusions DuPont has a long history of designing and engineering our own plants, often with low or zero harm. The results have been not only a safer construction phase but also assets that at the time of commissioning and beyond have an inbuilt PSM system delivered with the understanding and involvement of the operational personnel. Significance of Subject Matter The Oil and Gas industry in Australia continues to develop and engage in capital works that are expected to meet the balance of competing demands. This session discusses issues that are critical to a winning capital project: on-time start-up, design operating rates, and safe operation with optimum investment and life cycle cost.