Mechanical Integrity in the Oleochemical Industry

Category: News Published: Tuesday, 02 August 2016

Following on from last year’s Technical Workshop on the first Process Safety Management (PSM) element, Contractor Management, AOMG organized its 6th Technical Workshop in Malacca from July 27 – 28, 2016 on Implementing PSM Mechanical Integrity in the Oleochemical Industry. This year’s programme was very well participated with 31 delegates from all three member countries viz Indonesia, Malaysia and the Philippines. Two participants from PETRONAS also joined us. Participants had a wide range of roles covering maintenance, production, process and HSE with oleochemical experience ranging from 3 months to more than 20 years.

Our trainer was Ir V Gopinadhan, a mechanical engineer, with extensive experience in Shell and PETRONAS and a process safety trainer for various clients such as Shell, PETRONAS, IChemE and AOMG. He gave an overview of PSM before discussing the system and resources needed for MI (Mechanical Integrity) management. As a number of oleochemical plants are old implementing MI will assure not only their reliability but also safety. In taking participants through the process that included identifying critical equipment, Ir Gopi emphasized the importance of communication and documentation. At the end of the first day participants shared what they would be looking for during the study tour of PETRONAS Melaka Refinery Complex the next day. Participants reviewed the 6 cornerstones of process safety and agreed that the next workshop should cover Management of Change (MOC) or Workforce Competency & Engagement.

We were warmly received on the second morning at PETRONAS Melaka Refinery Complex in Sungai Udang and given a very comprehensive briefing on their PSM journey which began in 2002. Their Reliability & Integrity Management System (RIMS) began in 2004 to improve the low ULPO (Unscheduled Lost Profit Operability) of 45%. Key elements are top leadership commitment as well as ownership particularly by the operators. After lunch we were taken on a plant tour and we had more of our questions answered afterwards. The Refinery chose MOC as the first PSM element to implement due a number of incidents it was experiencing. It would establish a PHA (Process Hazards Analysis) baseline as well as a culture of change in their people. Before we left we were treated to a Malacca speciality viz Klebang original coconut shake. Thank you PETRONAS!

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