This paper describes the challenges faced by PETRONAS Carigali in implementing Process Safety Management (PSM) as part of the effort to enhance Health, Safety and Environment Management System (HSE MS) with process safety aspects in PETRONAS Carigali. This is a five year journey starting in 2006. Process safety management in PETRONAS Carigali is embedded within the Health Safety & Environment Management system (HSEMS). The HSEMS was introduced in PETRONAS Carigali in 1995 with the intent to standardize HSE management practices. Various practices from safety, health and environment were aligned, consolidated and initiated to form this structured system. Over time, staff and contractors' HSE awareness and practices improved. The occupational safety records indicate positive trends. However, process upsets and asset failures did not indicate similar trends. It was discovered that the assets and process safety aspects have not been adequately described and provided for in the system.


Eight process safety aspects namely Management of Change (MOC), Process Hazard Analysis (PHA), Process Safety Information (PSI), Pre Activity Safety Review (PASR), Mechanical Integrity (MI), Design Integrity (DI), Proprietary Licensed Technology Assessment (PLTA) and Operating Procedures (OP) were included in HSEMS enhancement. Concerted efforts were taken to review the HSE practices in engineering and operations to identify specific process safety gaps.

The uniqueness of this project is that it utilizes internal resources. The intentions were to build ownership, in house competencies and generate closer communication and sharing among the various operating units. The methodologies and lessons learnt could be used for similar purposes by others.

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