15 May Application of Operational Excellence in PSGAS Refinery Operations

What is Operational Excellence (OE)?

Operational Excellence (OE) is a systematic and integrated management of Health Safety, Security and Environment (HSSE) implemented in all aspects of business to achieve superior results in all operating units of the company. OE is a journey of an organization to achieve world-class performance with competitive advantage. The core of OE is leadership and ongoing efforts to build and maintain standards in a consistent and reliable way.

Some organizations have described the OE as an organizational ability to achieve and maintain leading performance in reliability and efficiency, adhering to the highest standards for safety, health, and environmental management performed in a Cost Efficient manner.

Typical Elements in Operational Excellence

The operational excellence management system framework is structured logically from the main focus and incorporated by the set of elements that articulate the goals and expectations of performance through the collection of programs, processes, procedures, and activities that in line with Process Safety Management (PSM). The main elements may not be the same for all organizations, depend on business structure and activities.

Leadership, Management, and Accountability

Management establishes policies and strategies, sets expectations and provides resources for successful operations. Expectations related to this element include Vision and Mission, Commitment to OE, Driving OE Culture, Resources, and Customer Focus.

Asset Management (Design, Construction, Operations, Maintenance, Inspection)

This ensures that critical asset performance is designed, manufactured, operated, inspected, and maintained to achieve high levels of reliability, integrity and efficiency throughout the life cycle of assets. Expectations related to this element include Design, Procurement and Construction, Identification and Assessment of Performance Critical Assets, Operations, Outages, Shutdowns, and Decommissioning, Quality Assurance, Improvements, Work Procedures.

Risk Management

Risk assessment and management requires things like Risk Identification, Assessment and Preparation, Risk Awareness, Business Continuity Management, and Risk Documentation.

Management of Change

Operating facilities should changes continuously to improve operating efficiency and safety, accommodate technical innovations, and implement mechanical improvements. In addition, sometimes, temporary fixes, connections, bypass, or other modifications may be made due to operating requirements. All changes in these operations, procedures, standards, materials, equipment, facilities or organizations may cause new hazards to be evaluated and managed to ensure risks coming up from these changes still at an acceptable level.

Pre-Startup Safety Reviews

The purpose of a pre-startup safety review or pre-startup safety reviews (PSSR) is to ensure that any changes made to the facility or process meet the design or operation objectives. PSSR aims to find changes that may occur during engineering design or during the construction phase of a project. PSSR includes not only equipment, but also “software” issues such as training and operating procedures.

By conducting PSSR, the organization performing the operation may refuse any facilities considered unsafe.

Human Resources and Training

Operation control depends on people’s competence. To achieve OE requires screening, selection, placement, ongoing assessment, proper employee training, and ensuring quality and experienced contractors.

Reliability and Efficiency

Three requirements are needed to create a reliability system for OE are:

• • • Ensure the process of indetification of the potential defect that will eliminate the work quality assurance system has been done.
    • The innovation process throughout the business is focused on optimizing productivity with the lowest cost, and the right output quality.
    • Management of the life cycle of a physical asset for stable and reliable operation holisticaly.

Product Stewardship

Product stewardship is a way that made anyone who designs, makes, sells, uses, and recycles or disposes of such products can help to protect the safety, health and environmental quality. This is a concept whereby everyone is involved in the life cycle of a product to share responsibility.

Compliance Assurance

Expectations of this process include identifying applicable requirements, communications and reporting, the settlement process of an existing violation and corrective action as a follow-up.

Emergency Management (Response and Incident Investigation)

Emergency planning and preparedness is essential to ensure some case, in the event of an incident, all necessary actions will be taken to protect the community, the environment, personnel and assets of the company. Including incident reporting and follow-up to take lesson learned.