gpca, dubai, november 28, · pdf file28.11.2017 · gpca, dubai, november 28, 2017...
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GPCA, Dubai, November 28, 2017
Detlef Kratz, Corporate Technology and Operational ExcellenceBASF SE
Managing Risk to improve Safety Performance
November 2017 | GPCA in Dubai
Ludwigshafen October 17, 2016
5 fatalities 1 boatman, 4 fire fighters28 injuries 6 severe, 22 light
November 2017 | GPCA in Dubai
North Harbor IncidentSequence of Events - What can we learn?
4 November 2017 | GPCA in Dubai
October 17, 2016
▪ Ongoing maintenance work on one pipe cleared for work
▪ Several other pipes in sleeper rack were in operation
▪ Wrong cut by contractor into Butylene containing pipe lead to leakage
▪ Ignition and fire due to sparks from angle grinder
▪ Explosion and rupture of Ethylene pipeline
▪ Other Pipelines overheated, opened or leaked and increased fire load
Measures
▪ Optimized marking methods to reduce risk of human errors
▪ Use of low-sparking tools to reduce risk of ignition
▪ Fire proof insulation to reduce risk of explosions
October 2017
▪ Ongoing investigation by the public prosecutor’s office
Communication News travel faster than facts are available
5 November 2017 | GPCA
Information
Clarity and facts
Channel to the public and own employees
Learn from mistakes
Proactive versus reactive
Avoid rumors
Impact
Image
Speed
Trust
Emotion
Safety related incidents not only impact the image of one Company but the Chemical Industry
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BASF Site and Technology PortfolioConstant change over 150 years through acquisitions & growthSafety Challenge from huge diversity and global footprint
6 November 2017 | GPCA
SingaporeKuantan
Hong KongNanjing
Freeport
Florham Park
Geismar
LudwigshafenAntwerp
São Paulo
Regional centers
Selected sites
Verbund sites
Selected research and development sites
Operations Footprint
~ 350 Sites
~ 1,200 Plants
~ 800 Technologies
~ 70 Bn € Assets
~ 30,000 People in production
Raw Material and Energy Footprint
~ 44 Mio tons of Raw Material
~ 59 Mio MWh
… to make
~ 37 Mio tons of Products
>> 10.000 Products
~ 17 Mio tons CO2
~ 0.023 Mio t emissions to waste water
TransparencyDo not hide behind statistics
7 November 2017 | GPCA
Key Performance Indicators
„Measure“ for Safety performance
Reporting
Guidelines
Not too many, not too complicated
Ensure compliance
Openness
Reward versus Punishment
Discipline
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Near Misses Number and potential severity
Process Safety Reviews Number and actions accomplished
Responsible Care Audits Monitor actions accomplished
Work Permits Regular Inspections
Follow and track leading indicators… ( surveillance)…to improve lagging indicators ( performance)
From Lagging to Leading Indicators
Process Safety Incidents (PSI)
PSI rate (2016): 2.0 2025 goal: < 0.5
Lost-time Injuries (LTI)
LTI rate (2016): 1.4 2025 goal: < 0.50
0.5
1
1.5
2
2.5
2010 2011 2012 2013 2014 2015 2016
Process safety incidents (PSI) Lost-time injuries (LTI)
Leadership You cannot delegate safety
8 November 2017 | GPCA
Empowerment
Ownership
Learning from mistakes
Adequate Resources
We sourceresponsibly
We drivesustainablesolutions
We respect people and treat them fairly
We produce safely for people and the environment
We produce efficiently
BASF operationsSuppliers CustomersCommitment
Personal priority for leaders and employees
Acknowledge local culture and understand diversity of needs
Sustainability Roadmap – Corporate Commitments
Change perspective
from “managing safety” to
“managing risks”
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Managing RiskRisk awareness is key
9 November 2017 | GPCA
Cu
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catastrophic incidents
Awareness
Understanding probability and severity
Correct classification
Mitigation
Urgency
Correct measures
Process and OccupationalSafety
Fatalities
LTI
PSI
Non LTI
Small PSI
AFPD
Near Misses
Synergy of Operational Excellence and SafetyA reliable plant leads to less incidents; Continuously update existing and investment in improved technologies
10 November 2017 | GPCA
People
Expertise in EHS, Technology and OpEx
Flexibility in diverse assets
Organization
Balance central versus local/regional
Clear Roles & Responsibilities
Continuous Improvement Mindset
Safety Initiatives
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More than 50% of all Process Safety Incidents occur in ~10% of plants
Initiative Management
Sharing and using Datato improve safety
Safety 4.0Embrace Digitalization and Big Data
11 November 2017 | GPCA
Opportunities
„Google“ Platform for Safety
Digital Plant to avoid communication errors
Future
Establish Exchange Platforms
Smart Manufacturing
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ExampleDigital permitting isolation and hazard assessment
Systematic control / approval of work flow
Risk assignment to job tasks
Transparency by holistic view on jobs
Accountability of tasks and actions
Benefits
Risk/hazardAssessment
Isolations
Permit
Inte
grat
ed
pro
cess
Mobile devices support our workforce
Big data used for predictive risk
Data driven risk assess-ment & maintenance
12 November 2017 | GPCA
Industry-wide CollaborationA strong Business Case for Safety !
A global supplier engagement program that assesses and improves sustainability sourcing practices (ecological, social, safety)
Inclusiveness
Joint approach
Advocacy
Exchange
Establish and nurture Industry Platforms
Common Understanding of Risk
Open Dialogue within Industry and with Authorities
Share & LearnCu
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European Process Safety CenterProcess Safety Network of major companies in Europe
Center for Chemical Process Safetybelongs to AiChE, books, conferences
International Process Safety GroupCompany Network for Incident sharing
Managing RiskTransparency, Communication, Leadership, Operational Excellence, Digitalization, …
13 November 2017 | GPCA
Managing Risk calls for a culture built on trust within a company but also openness to learn and share through collaboration within the chemical industry
High severity incidents can only be avoided by continuously maintaining
➢ a high level of awareness and common understanding of risk
➢ an in-depth set of competencies and technological know-how and
➢ well understood and user friendly EHS core processes
