Process Safety Management
Our Policy
Process safety management is the framework of systems and processes for the robust design, engineering, operating, and maintenance practices needed to prevent the leakage of flammable liquids or other hazardous substances, or the occurrence of MAEs, such as fires and explosions that may occur from such leakages.
By thoroughly managing process safety, we endeavor to prevent leakages from the processes of our facilities.
Thorough Implementation of Process Safety Management
As shown in the figure below, our process safety management consists of four focus areas and 20 elements. Each element has a detailed set of expectations to which operator projects must adhere. Within the process safety management framework, we prevent process leakage-related MAEs at facilities through systematic identification and assessment of risks. We have also voluntarily adopted a Safety Case regime at our operational facilities. This documents implementation of sufficient measures to reduce impact in the event of MAEs, and ensures risks are maintained to the ALARP level.
In FY2022, we created the 2023–2027 Roadmap for Ongoing Improvements to Process Safety Management. With the aim of systematic implementation of ongoing improvements, this roadmap outlines the process involved in bringing all organizations in the Group up to the same level of maturity in five priority areas by FY2027. This roadmap is being applied from FY2023 onward to strengthen our process safety management. In FY2023, we developed a mechanism for achieving Group-wide process safety management competency and published new change control requirements. We are also applying our process safety knowledge to the fields of hydrogen, ammonia, and CCUS.
Process Safety Management Framework
Process Safety KPIs
We collect and report Tier 1 and Tier 2 process safety events (PSEs1) to quantify our process safety management performance. In FY2023, one Tier 1 and two Tier 2 PSEs occurred. We also set and monitor Tier 3 and Tier 4 leading KPIs for operator projects to help further prevent process leakages. We aim to improve the reliability of operations by collecting and analyzing data on process safety KPIs, drawing learning from past leakages to prevent recurrences, pinpointing trends in accident-causing factors, and—as a leading KPI—monitoring the implementation rate of actions that help to prevent leakages. At the same time, we share information on our process safety performance with stakeholders to avoid complacency and raise awareness of the importance of MAE prevention.
1 Tier 1 and Tier 2 process safety events (PSEs): Tier 1 and Tier 2 PSEs are unexpected releases or leakages of any material, including flammable liquids. In line with internationally accepted guidelines, we classify and report such events as Tier 1 or Tier 2 depending on the degree of consequence (personal harm, direct cost to the Company, type and quantity of material released, etc.). We have also adopted Tier 3 and Tier 4 classifications as leading KPIs, referring to internationally accepted guidelines.
Asset Integrity Assurance
An Asset Integrity/Process Safety (AIPS) assurance review is a systematic series of reviews conducted by an independent team at appropriate points during each phase of a project. Specifically, this process assesses the actions implemented at a site to fulfill the expectations embodied in the 20 elements of process safety management. Benefits that can be expected from an AIPS assurance review include the following:
- Providing assurance to senior management and stakeholders that asset (equipment) value is being adequately protected
- Confirming our equipment meets AIPS management requirements
- Sharing good AIPS practices and learning from project to project
In addition, we conduct other reviews at each phase of the project, including reviews ahead of facility launch and operational readiness reviews. By tracking progress in the implementation of recommendations generated from these reviews and providing feedback on areas for improvement, we endeavor to enhance the integrity of our assets.