How can I safeguard my plant against risks?

Imagine that you have an efficient process design, which has been thoroughly evaluated in detail on Loss of Primary Containment (LOPC), release of energy, emissions to the environment, hazards for health and safety for your own personnel and neighbors. Also the risks for your supply chain (business) and damage of reputation of your company have been considered in this design. Imagine also that all unacceptable risks that were revealed in this evaluation are adequately mitigated and incorporated in the final design (findings from the HAZOP). All required licenses were requested and obtained and the plant is exactly build and subsequently commissioned according to this final design. The plant is operated by well-trained personnel, who all work according to well established and described Standard Operating Procedures.

But….how can you now ensure that this initial safe and secure situation is maintained? After all, there are dangers lurking everywhere!

Just to mention a few:

  • Personnel does not follow the work instructions and procedures (Safety Culture)
  • Equipment is replaced by another kind or type than in the original design was included. (Management Of Change)
  • Equipment does not last forever and will thus eventually fail (Mechanical Integrity & Reliability)
  • Signals of (almost) exceeding the process conditions and specifications are ignored (Metrics, Safety-KPI’s)


This list in reality is, unfortunately, much longer. It’s even so long, that it is difficult to get focus and set the right priorities. This is hard because your plate might be spilling over with the daily routine of “putting out fires”.

Process Safety Excellence

Bilfinger Tebodin developed a program: “Process Safety Excellence” (PSX), which is based on a so called “Process Safety Gap Assessment” model. This model quickly shows which risk you run and the Process Safety element. Apart from that, PSX provides you with the required “toolkits” to close the identified gaps, while securing you against new Process Safety hazards could otherwise sneak in again.

Toolkits for making the right choice

Together with the management team of your plant, we use the PSX model as a tool to identify which areas of your organization run the most serious and hazardous risks. The twenty well established “Risk Based Process Safety” (RBPS) elements serve as basis for this model. The evaluation provides a clear overview, which is quite useful for subsequently setting priorities for the corrective actions. The measures that have to be taken require knowledge and skills. Knowledge can be passed on by means of training and are secured by frequent toolbox meetings. Skills are typically obtained by practice in the field. The toolkits not only contain the required training materials, but also the relevant procedures and checklists for each RBPS element. Bilfinger Tebodin can even tailor these procedures and checklists for you, so they fit right into the present management system of your company.

Securing safety and reliability for the life time of a plant is not easy, but our PSX concept certainly provides a good help to achieve this!

Read more about Process Safety Excellence.

Would you like to have more information or to discuss the Process Safety of your new process design, then please visit our website, or just contact me:

Bart Luger

Senior Consultant Process Integrity & Safety

Bilfinger Tebodin

+31 6 10 96 32 63


Аuthor: Bart Luger

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