Inherently Safer Design (ISD) is a powerful tool which offers not only significant reduction in the risk of process safety incidents, but can also provide operability benefits and improved cost performance. There are many examples of where ISD changes have been successfully and cost-effectively made in existing plants, and this paper shows how ISD concepts can be applied to process operations in existing facilities. This paper highlights success stories from industry where ISD concepts were applied to existing operations/facilities, which resulted in not only improvements in safety, but in process operability and cost performance.