Chemical manufacturing

Chemical manufacturing case study – Wesfarmers Chemicals, Energy & Fertilisers (WESCEF)

Process Safety, Safety Risk Management

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The RiskView system was easy to develop into a working system. Information from previous HAZOPs were easy to input and now provide significant improvements in our flexibility to update and modify if changes are made in the plant. The bowties are much more intuitive for understanding risk scenarios and identifying critical control measures.Bob Gregorovich, WesCEF Process Safety Superintendent

Background

CSBP/WESCEF required a risk management solution to simplify process hazards analysis across its chemical manufacturing plants. The process safety team were managing safety cases and were looking to make this more efficient.

Online collaboration was important. The business had existing software systems in place but it was identified that updated software tailored to hazard and operability study (HAZOP) applications would assist analysis and operating efficiency.

The client’s risk team also wanted to identify critical risks, and automatically filter these out for inclusion in safety cases. This was particularly important given the variety of inherent risks in fertilisers, gas, fuels and chemical manufacturing.

Solution

RiskView was ideal for WESCEF as an off-the-shelf purchase with very little customisation required. The bowtie analysis and HAZOP software modules were deployed with the initial rollout.

The client was able to switch over to process hazards analysis using RiskView with limited disruption to normal practices. New safety cases and bowtie analysis are done with RiskView, with plans to migrate existing data into the system over time.

The Meercat team provided on-site support where necessary to assist with the implementation of the software package. This included training and bowtie setup.

Outcome

WESCEF was able to improve the efficiency of HAZOPs and safety cases using RiskView as a complete process hazards analysis software package.

Users found RiskView to be intuitive and user-friendly, which greatly assisted with implementation. Stakeholders including risk managers, safety advisors and engineers have been brought into the system. Reducing the time taken on risk management documentation allowed the process safety team to focus on other matters.

WESCEF also benefited from having a central system to securely store risk knowledge, which reduced re-work with new safety cases. This also assisted with improving long-term risk monitoring of critical risks.