Module 2.3.2.

Safety Management System

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 Challenge to Safety Management
• Complex Processes
• High Pressure
• High Temperature

• Large inventory of flammable

substances
• Demand on reliability

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 Safety Management System
• Established in Towngas for a long time
• Cover all 14 elements required by the F & I U (Safety
Management) Reg.
• Modern management concepts are considered important to
success of the SMS

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 Safety Policy
Top management commitment and alignment with
company value are quintessential

• In line with company mission:

– Provide ….. a safe, reliable supply of gas ……
– pose no risk to ….. safety of employees, contractors,
customers and the public
• Managers' performance will be judged by the safety
performance of their unit
• All employees and contractors are responsible
• Endorsed by Managing Director

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 Implementation Structure
• SMS integrated with line management structure and
provided with professional supports

Managers of departments / sections held overall

responsibilities for safety performance
Supervisors carry out implementation and control of
safety & health measures
Front-line employees follow instructions and procedures

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 Implementation Structure
• Plant internal safety personnel:
– provide advice and support, carry out specific studies or
investigation, organise training courses, etc.
• Corporate safety personnel:
– provide more general support, such as distribution of
legal information, audit work, company-wide training
and promotion
PLAN

DEV
AUDIT

ORG MEAS

IMP
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 Training
• Use good information management aids

Training Matrix, database system

Basic training categories:
Mandatory
Operational (PTW, process safety, chemical handling)
Emergency response
Safety knowledge, accident experience, etc.
Thro' both internal and external training

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Training

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 In-house Safety Rules
• Work Instructions control under ISO9002 or 14001,
developed based on full analysis of process map /
aspects

Define operation, maintenance, safety,

environmental and emergency
procedures
Communicated to employees by
briefing, internal training courses or on-
the-job training

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In-house Safety Rules
• Review / revision upon significant changes in work
processes / facilities or observation from incidents
and practical exercises

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 Inspection
• Appropriate focus and frequency according to
risk impact, and with timely follow up

Operational patrol
every 2 hr
focus: equipment failure,
imminent hazards, PTW,
contractor works
immediate corrective actions

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Inspection
• Weekly plant safety personnel inspection
– on process / occupation safety & health, emergency
facilities
– immediate notification to supervisory management for
rectification
• Quarterly corporate safety personnel
– on occupational safety & health, independent nature
– immediate verbal advice and memo to department
management for proposed action
• Technical inspections by engineers / consultants
– on equipment conditions
– e.g. tanks, lifting appliances, pressure vessels,
pipelines
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 Hazardous Exposure

• Require detail hazards information:

– process knowledge and MSDS
– gas measurement
– laboratory analysis
• Engineering control as far as practical, but may need time
for modification
• PPE as interim measure before engineering control
becomes available, but usually maintained as basic line of
defense

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 Accident Investigation
• Emphasis on correcting root causes:
– equipment, technical or design problem
– procedure or management system deficiency
– communication (very common pitfall)

Carry out by supervisor / engineer and plant safety

personnel; corporate safety personnel if necessary
Accidents / near misses
Line management issue report and recommendations

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 Emergency
Planning and practice are most important

• Three tiers of contingency plans:

– Corporate Emergency Plan (coordinate
resources and communication of whole
company)
– Departmental Major Emergency Plan
(coordinate resources and
communication of the department)
– Emergency Procedures for front-line
handling various foreseeable situations
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Emergency
• Plant Emergency Response Teams - received
formal fire fighting training
• Regular drills / exercises:
– fire drills with FSD
– evacuation drills
– chemical / oil spill exercise
– table-top exercise

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 Subcontractor Control
• Annual subcontractor assessment by section supervisor thro'
ISO9002 system
– safety performance included
– poor performance subcontractor may be removed from list
• Subcontractor experience important in selection:
– familiar with plant design and environment
– understand well plant's PTW and safety rules
• For new subcontractor, Safety Work Instruction is issued and
briefed; close supervision by plant personnel
• All PTW is applied by plant person-in-charge, not
subcontractors, to ensure direct supervision

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 Safety Committee

• Long existing and provide a good forum for different

disciplines to express concerns and suggestions
• Over half members act as worker representatives
• Rotation every 2 years to increase involvement and
fairness

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 Hazards Evaluation
• Special evaluation required for process safety:
– HAZOP (for equipment major modification, new
process facilities, etc.)
– QRA (review public risk)
• Job safety analysis / risk assessment:
– mandatory (noise, manual handling, confined space)
– dangerous chemicals handling or special operations

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 Awareness Promotion

• Notice boards
• Production Newsletter
• Tool Box Talks
• Communication sessions
• Company Safety & Environmental Bulletin
• Safety & Environmental Day
• Computer screensaver
• Safety Quiz Competition, Forklift Truck Driving
Competition

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 Accident Control & Hazard
Elimination Program
• Always built in project management system
and O&M programs:
– Modification Review Committee
– Overhauls Team
• oversees safety measures;
• require Clearance Certificate for
isolation;
• specific procedure for high risk job, e.g.
tank decommissioning
– Major project group consists of safety
functions

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 Health Program
• Health protection program is covered by in-house safety
rules, hazardous exposure identification, hazards
evaluation and elimination elements
• Health examination may be required for:
– mandatory requirements
– risk control measures' effectiveness uncertainty
– complaint or sickness occurrence

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SAFETY IS OUR
PRIORITY

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 END
Thank You

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