Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Mitigating Operational Risk and Achieving Compliance in a Multiline Petrochemical Complex
- Petrochemical Complex (Aromatics, Polymers, Solvents)
- Large-scale complex operating multiple production lines
- MENA Region
Obstacles Our Experts Have Transformed into Opportunities
The client—operating a complex facility with multiple product lines—faced escalating safety and compliance risks:
Tier-1 Near Misses
Two serious near-miss incidents in less than a year, prompting internal audits and regulatory scrutiny
Outdated HAZOP Studies
Existing studies were incomplete and not integrated into daily operating procedures
Lack of SIL Verification
Safety systems lacked proper Safety Integrity Level (SIL) analysis and process hazard documentation
Unverified Emergency Response Plans
Plans were generic and not tailored to plant-specific risks
Upcoming Compliance Audit
The plant was at risk of shutdown or penalties unless immediate corrective actions were taken
Need for Proactive Risk Management
The client required not just compliance, but a sustainable and robust risk management culture
Teec’s Expert-Led Solution: Operations & Maintenance Excellence
Our Team of Experts introduced their Safety & Risk Assurance service to build a comprehensive, proactive safety management framework:
What Our Experts Did
Conducted a full Process Safety Management (PSM) audit, identifying gaps in hazard identification and compliance reporting.
Facilitated updated HAZOP and HAZID workshops with cross-functional teams from five production lines
Completed Safety Integrity Level (SIL) analysis, redesigning safety instrumented functions (SIFs)
Developed scenario-based Emergency Response & Crisis Management Plans, including chemical leak, fire, and toxic release drills
Delivered on-site training for operators, supervisors, and safety officers on process safety best practices
Created a cultural shift from compliance-reactive to risk-proactive, ensuring ongoing ownership and accountability
Execution Approach by Teec’s Experts
- Reviewed existing safety documentation, audit reports, and near-miss logs.
- Conducted structured interviews across operations, maintenance, and HSE teams.
- Developed a PSM gap matrix covering 14 key elements of process safety
- Facilitated HAZOP and HAZID workshops with critical units’ stakeholders
- Conducted SIL classification and verification using LOPA (Layer of Protection Analysis)
- Developed a register of Safety Instrumented Functions (SIFs) with test intervals and validation plans
- Created new, scenario-based Emergency Response Plans (ERP), including drills for chemical leaks, fires, and toxic release
- Reviewed regulatory compliance obligations and created a unified audit readiness tracker
- Developed compliance control procedures aligned with OSHA, EPA, and local regulations
- Trained shift leaders, engineers, and EHS staff on PSM roles, risk escalation protocols, and critical controls
- Assigned risk ownership by department and introduced a monthly Safety & Risk Performance Dashboard
- Conducted live emergency drills observed by regulatory authorities
Results & Impact
Achieved zero recordable incidents in the 6 months post-implementation
Regulatory audit passed with zero non-conformities, a first for the site
Reduced time to resolve safety action items from 23 days to 6 days on average
SIL compliance implemented for 100% of critical loops in targeted units
Integrated Value Through Teec’s Data-Driven Solutions
Enhanced by Compliance & Risk Management Integration (BPM Solutions)
This integration allowed the organization to embed risk thinking into daily routines—not just safety manuals.
