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Thesis (D.Tech. - Electrical Engineering, Dept. of Process Control and Computer Systems, Faculty of Engineering and Technology)--Vaal University of Technology. / In recent years, industrial plant maintenance has changed dramatically. These changes are due to a considerable increase in the number and variety of physical plant assets, increased design complexity, new maintenance techniques and changing perspectives regarding on how to perform maintenance effectively. Managers at modern process plants are becoming increasingly aware of the extent to which equipment failure affects safety and the environment. Process plant personnel are limited in their ability to accurately and consistently evaluate the health of plant assets. Due to poor record keeping, maintenance staff often has little defence against aging equipment and asset failures. As a result companies have undertaken to implement planned equipment maintenance schedules and install new technology to allow for efficient tracking and analysing of equipment health across the board. The introduction of an integrated asset management solution is presented in this thesis. The integrated asset management solution will assist maintenance staff to cost-effectively predict the probability of asset failure prior to the occurrence of any actual plant incidents. The integrated solution documented in this thesis will be implemented at the Sasol Solvents site to enhance plant availability, maximum up time for all plant assets and plant safety. Strategic Asset Management Inc. (SAMI) uses the Operational Reliability Maturity Continuum model to improve profitability, efficiency and equipment reliability. The SAMI empirical model employs various stages to address improved performance and asset management and was used as a guideline to develop an integrated solution to optimise plant performance and profits. The integrated asset management solution, documented in this thesis, was developed with the intended function of bringing information from diverse plant based systems and field equipment to the maintenance personnel in an understandable interface so that the information can be used to improve the reliability and availability of all plant assets.

The management of health and safety risks in the oil refinery tends to be centred on the collection and simulation of technical data which can then be used to make decisions on the wellbeing of the workforce as well as the refinery installations. While the number crunching in the process is immensely vital, there tends to be a problem of ignoring or, at the very least, side-lining the social-cultural values of the people dealing with health and safety risk assessment processes. The economic driver for the operation of the oil refinery tends to be more important because of the generally huge initial financial outlay, and the eventual high costs of maintenance; hence health and safety risk management should have evidence of ensuring that the installations, as well as the people that work in them, are well catered for. In the Kuwait Gulf Oil Company this problem is more evident in newer installations where lean management processes have been instituted by oil firms so that they can reduce waste in the oil refining process without compromising the occupational health and safety needs of the refinery. Therein lies the initial problem of integrating health and safety risk assessment processes because most approaches concentrate on the technical elements of waste elimination while ignoring the social-cultural factors that impact on the health and safety of the workforce. This is an exploratory piece of research that examines the impact of rational and cognitive decision theories – herein called the psychology of risk – and how they impact on the occupational health and safety systems in the oil and gas refining sector of Kuwait. The research concludes that the application of lean concepts in the oil refining process is noble in itself but it needs to be integrated with the rational and cognitive detection factors that are necessary to incorporate and support the social-cultural tendencies of the workforce. The research recommends a framework for incorporating social-cultural values in the decision making process pertaining to health and safety risk assessment in oil refining process plants. Key Words: occupational health and safety risk assessment; lean management; social-cultural values; rational and cognitive decision making; oil and gas process plants.