Process safety

All employees, each in their own area of work across different industry sectors and services, are responsible for process safety.

Process safety relates to all activities spanning the life cycle of a given process facility (e.g. a production unit or storage tank), carried out during its design, construction, operation, maintenance, repair, modernisation, closure and decommissioning.

The safety of the process and of the personnel involved is equally important. Independent experts have confirmed that PKN ORLEN’s process facilities are properly designed, built, operated, repaired, maintained and upgraded. We maintain the highest OHS standards and comply with all applicable laws, regulations and rules.

Priority is also given to continuous efforts aimed at the prevention of fires, explosions and releases of hazardous chemicals from industrial installations at chemical plants, refineries or storage facilities for petroleum products. In order to prevent such emergencies, our facilities are fitted with a number of safeguards and control systems, including process control and metering, alarm, lock-out/tag-out, fire and explosion protection systems, which are subject to regular inspections and maintenance procedures.

All employees, each in their own area of work across different industry sectors and services, are responsible for process safety. Employees working on process facilities play an important role in ensuring safe and responsible operation of their respective installations and, by extension, of the entire plant, taking account of the following aspects:

  • Safe operation of machines, instruments, installations and facilities depends not only on their proper design and structure, but for the most part on the awareness of their operators of the harmful effects of hazardous substances processed by and stored at a given facility, and their sense of responsibility for their own safety and safety of the plant’s installations and environment;
  • Active role of employees at a production plant consists in a continuous care for workplace safety and supervision of equipment to ensure optimum safety level, as well as strict compliance with OHS and fire prevention laws and regulations;
  • Contractors and employees of third-party companies should be instructed that unauthorised persons are not allowed to stop, move or repair any safety devices or systems;
  • Employees are not allowed to tamper with any devices, machines, valves, pipes, electrical equipment and other instruments unless they have necessary authorisations and required experience.

To raise the awareness of potential threats, emergency response procedures and proper OHS conditions, ORLEN organises training sessions for employees working at its production units or responsible for other areas of its operations. It is vital that all plant operators, fuel terminal staff members, chemical rescuers, OHS officers and Company Fire Brigade members have the necessary training, experience and expertise.

The Company regularly identifies process threats, analysing and assessing the security of process units.

The purpose behind those efforts is to determine the mutual relations between existing threats and applied safety and protection measures. Risk levels, once defined, are one of the crucial factors taken into account when deciding whether the security measures applied are sufficient and ensure adequate protection against major failures or whether additional safeguards need to be implemented.

Supervision and ongoing monitoring of the Płock Production Plant units are carried out through (if applicable):

  • The DCS system (or other operational control system);
  • The ESD system for safe emergency shutdowns of equipment, plant or installations after the maximum permitted operating parameters are exceeded;
  • Gas detection, fire-fighting and CCTV systems;
  • D7i programme;
  • Routine inspections of all units;
  • Maintaining records in Operator’s Logs, Foreman’s Logs, and the Register of Instances of Non-Compliance with the Process;
  • Audits performed during the Health and Safety at Work Day.