Safety Critical Equipment Register

Purpose. Lists the equipment and systems that the safety case relies on to prevent or mitigate a major accident, with the performance standard, the test or inspection frequency and the current status of each item.

1.Scope

This register covers safety critical equipment at the Kwinana plant and the Kwinana Beach terminal. An item is safety critical if its failure could cause or contribute to a major accident or if it is relied on to limit the consequences of one. Items are grouped by the major accident hazard they control.

2.Register entries

Each entry must show the tag number, the description, the major accident hazard it controls, the performance standard it must meet, the test or inspection method and frequency, the last test date, the next due date, the current status and the responsible discipline. Overdue items must be reported weekly to the Process Safety Manager and the site leadership team.

3.Principal groups

The following groups make up the register. The full item list is held in the maintenance system and is reconciled with this register quarterly.

• Reactor pressure relief valves and rupture discs, inspected and tested annually
• Reactor high pressure and high temperature trips, function tested every six months
• Solvent recovery column emergency shutdown system, function tested every six months
• Tank high level alarms and high high level trips, tested every three months
• Emergency block valves on acid, caustic and solvent lines, stroke tested monthly
• Acid and chlorine gas detectors, calibrated and bump tested monthly
• Firewater pumps and ring main, run tested weekly and flow tested annually
• Bund integrity and bund valves, inspected weekly
• Scrubber circulation and pH control, checked every shift

4.Deferral of a test

A test or inspection will only be deferred with a management of change request approved by the Maintenance and Integrity Manager and the Process Safety Manager, with compensating measures recorded. A deferral must not exceed 25 percent of the test interval.

5.Failed tests

An item that fails its test must be recorded as a process safety event, repaired or replaced before the plant relies on it, and the safety case owner must assess whether operation can continue in the meantime with compensating measures.

6.Review

The register must be reviewed after every management of change that affects safety critical equipment, after every failed test and at least annually with the safety case review.