ri report appe morocco 20150317
TRANSCRIPT
Aon Risk Solutions Global Risk Consulting Risk Control & Engineering
Risk Improvement Report
Artenius PET Packaging Morocco
El Jadida
March 2015 Prepared by: Pierre-Marie Thivel Senior Consultant Global Risk Consulting
Proprietary & Confidential | Aon UK Limited is authorised and regulated by the Financial Conduct Authority
APPE Artenius PET Packaging Morocco
El Jadida
Table of Contents 1. INTRODUCTION 1
2. EXECUTIVE SUMMARY 2
3. RECOMMENDATION PRIORITY GUIDELINES 4
4. RECOMMENDATIONS 5
2015.1-A2 ATEX Study 5 2015.2-A1 Electrical continuity reinforced inspection 5 2015.3-A2 Water supply of the fire protection 5 2015.4-A1 Hot Work Permit 6 2015.5-B2 Main low voltage switchboard partitioning 7 2015.6-B1 Retention means under oil drums 7 2015.7-B2 Retention means under machines 8 2015.8-B1 Battery loading in the vicinity of the SX500 machine 8 2015.9-B3 Install automatic fire detection throughout the plant 8
Aon Risk Solutions | Global Risk Consulting | Risk Control & Engineering
APPE Artenius PET Packaging Morocco
El Jadida
Disclaimer "This report and any recommendations in it are based on certain observations made by us and/or from information supplied to us from sources which Aon believes it is entitled to assume are reliable. Conditions may have changed since our survey and/or the preparation of this report, and the reader must take this into account when acting in reliance on it. It is not, and is not intended to be, exhaustive or conclusive, covering every hazard or risk potential, nor to guarantee compliance with any statute or regulation, nor does its preparation and submission to insurers relieve you of your obligation to make full disclosure of all material facts to your insurers. It is offered to assist you in your assessment and/or management of risk. If you are in any doubt as to whether a fact is material and should be disclosed to your insurers, you should promptly discuss this with your insurance broker, if at all possible prior to the binding of the insurance contract. "
Senior Consultant …………………………………………….. Pierre-Marie Thivel For and on behalf of Aon Risk Solutions Global Risk Consulting 20 April 2015
Confidentiality Clause
“The information contained within this document is confidential to both Aon Risk Solutions and Artenius PET Packaging Morocco and has been produced solely for the purpose of our discussions regarding the latter's insurance programme. The contents may not be reproduced or disclosed to any third party without the prior written approval of Aon Risk Solutions and Aon Risk Solutions disclaims any liability whatsoever to any such third party. Please also read the important notes above". Copyright - Aon plc 2015.
Aon Risk Solutions | Global Risk Consulting | Risk Control & Engineering
APPE Artenius PET Packaging Morocco
El Jadida
Site Visit Details
Group Name: APPE
Subsidiary Name: Artenius PET Packaging Morocco
Site Address: 83 Zone industrielle d'El Jadida 24000 El Jadida Morocco
Occupancy: PET preform plant
Conferred with: Rachid Afelad : Plant Manager Nezha El Amrani : H&S Manager and Sales Manager Lahcen El Moussafir : Production Manager Mohammed Latif : Maintenance Manager
Site Contact Details: +212 523 354 544
Prepared By: Pierre-Marie Thivel
Consultant’s Contact Details: Aon Risk Solutions Global Risk Consulting – Risk Control & Engineering
Office: +33 1 47 83 05 58 Mobile: +33 6 59 28 20 44 E-mail: [email protected]
Date of Visit: 17th March 2015
Document Ref: RI Report APPE Morocco 20150317.docm
Document History Rev No: 0
Aon Risk Solutions | Global Risk Consulting | Risk Control & Engineering
APPE Artenius PET Packaging Morocco
El Jadida
1. Introduction Aon would like to take the opportunity to thank all concerned for the assistance and co-operation extended during this visit.
This Risk Improvement Report has been prepared following inspection of the premises, discussions with management and relates to conditions observed at the time. The purpose of this report is to assist in reducing the possibility of loss from the risks assessed.
The risk improvements contained in this report are of an advisory nature and reflect good risk management practice. They were all discussed with site management prior to leaving the site.
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APPE Artenius PET Packaging Morocco
El Jadida
2. Executive Summary
Fire The plant, erected in 1999, is constructed with light non-combustible material. The main building is not partitioned with fire wall.
As the plant is dedicated to the manufacturing of PET preform (carbonated soft drink and mineral water), the contents are combustible solid. However the ignition sources are minimized (thermography controls for instance) and the protection means are available: fire extinguishers and fire hoses. The water supply should be improved to reach an adequate standard of protection. So the MPL/MFL scenarios are similar and include the whole site.
The risk of high temperature is under control by the safety devices with automatic shutdown.
Although the PET pellets contain normally no dust, we should consider the potential presence of PET dust inside the transportation system (2 hoppers, 2 silos and ducts). As the PET is a strong insulating material (electrostatic skill), the transportation installation is grounded. No ATEX study is available according to the site and no information about the presence of explosion vents on silos.
No flammable liquid storage, no natural gas. No loss reported by the site.
Business Interruption The process is composed of five Husky independent lines/machines. The highest capacity machine is able to manufacture 90 millions of preform per year compared to the whole plant nominal capacity of 350.
The site has a unique building for production and storage. The interdependency with the other APPE plants is low (only 3% of the turnover is supplied by them). The moulds are key equipment but the majority is also available on Spanish, English or French sites. The critical utilities are electricity (no emergency generator) and cooling units (spare one is designed for 4 machines only). The suppliers are not critical as there is at minimum double sourcing except for the nylon (1% of the turnover).
In case of machinery breakdown or fire throughout the site, the production will be transferred to APPE Toledo plant. The finished products represent roughly 2 to 3 weeks and the time needed to transfer the production is about 10 days.
There is no business continuity plan available. However the group monitors the production features of each site by a database (machine, mould, capacity).
Perils The neighbourhood is composed by facilities in the field of food industry, pharmaceutical industry and clothing industry. The nearest building is located at more than 10 m.
This area is normally not affected by heavy windstorms. Although the site is located in a coastal area which may pose an exposure regarding tsunami (source: Munich Ré). The site is located at 4 km to the sea at an elevation level of 27 meters compared to sea level. There is no open water in the vicinity. The risk of earthquake is low (Zone 0: MM V or below, source Munich Ré). The risk of lightning is low (less 2 impact/km²/year, source Munich Ré).
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APPE Artenius PET Packaging Morocco
El Jadida
The natural hazard is low in general.
The political risk in Morocco is low. No major riot was occurred in this area in the past.
The nearest airport is located at 100 km in Casablanca. The risk relating to aircraft is low.
Security The contents (raw material and preform) are not attractive. The maximum stocks are 180 t for the PET resin and 25 millions of preforms. The plant is enclosed by a 2 m high wall topped by barbed wire. The unique access to the site is normally closed. The electrical premises (transformer and main low voltage switchboard are locked closed. As the site is constantly attended by the employees (minimum of 2 persons during the night), the site is not provided by an intruder alarm. The site is equipped by 16 CCTV cameras throughout the site. The data is saved onsite and accessible remotely by a safe access.
The brand new computer equipment is composed by an IT server (dedicated room) with automatic backup system to the group database. No strategic confidential information: PET preform is a well-known process.
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APPE Artenius PET Packaging Morocco
El Jadida
3. Recommendation Priority Guidelines
A A situation or practice likely to lead to; loss of life or permanent disability, extensive damage to property, critical interruption to operations or substantial financial loss. Material breach of regulations.
B A situation or practice likely to lead to; serious injury or illness, considerable damage to property, interruption of operations or considerable financial loss. Inadequate compliance with regulations.
C A situation or practice likely to lead to; Minor injury or illness, non-disruptive damage to property and/or moderate financial loss.
Timescale Codes
1 Matters to which IMMEDIATE attention should be given. Either due to the need for URGENT action, or the SIMPLICITY of completing the recommendation.
2 Matters requiring approval or involving moderate costs. A timescale of THREE TO SIX MONTHS would be appropriate.
3 Matters to which improvements need to be made AS SOON AS PRACTICABLE.
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APPE Artenius PET Packaging Morocco
El Jadida
4. Recommendations
A A situation or practice likely to lead to; loss of life or permanent disability, extensive damage to property, critical interruption to operations or substantial financial loss. Material breach of regulations.
Timescale Codes
1 Matters to which IMMEDIATE attention should be given. Either due to the need for URGENT action, or the SIMPLICITY of completing the recommendation.
2 Matters requiring approval or involving moderate costs. A timescale of THREE TO SIX MONTHS would be appropriate.
3 Matters to which improvements need to be made AS SOON AS PRACTICABLE.
2015.1-A2 ATEX Study
We recommand to carry out an ATEX study in order to analyse the explosion risk linked to the potential presence of PET dust. In general, the risk of explosion exists if the PET dust is under 400 µm. The minimum ignition energy is very low (about 10 to 15 mJ). The explosion could occur in the transportation system (vacuum pump) from the hoppers to the both silos and to the drying sections. No information about the presence of explosion vents on silos.
2015.2-A1 Electrical continuity reinforced inspection In order to limit the likelihood of static electricity accumulation and discharge on the powders transfer lines, we recommend to reinforced the visual inspection relating the electrical continuity on the PET pellets installation (transfer pipes, hoppers, silos, drying section).A deficiency has been detected during the tour.
2015.3-A2 Water supply of the fire protection An adequate water supply should be provided at this facility for fire protection purposes. The current supply is a tank of 12 m3 and an electrical pump of 8 m3/h. The fire risk analyse carried out last year recommend to install a 120 m3 water tank, a diesel pump of 60 m3/h and hydrant throughout the site. This will be acceptable regarding the fire risk.
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APPE Artenius PET Packaging Morocco
El Jadida
2015.4-A1 Hot Work Permit The site has set up a permit to work system. We recommend to had a specific permit for the hot work like welding, cutting and all work with risk of sparks generation. It should include the expiration date and time (not beyond one day). The safe area around the area of hot work should be 10 m. A constant fire watch should be continued for half hour after hot work work is completed and the area should be monitored for an additional one hour and half after that. Space should be available in the form for the signature of the hot work supervisor after the watching and monitoring periods.
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APPE Artenius PET Packaging Morocco
El Jadida
B A situation or practice likely to lead to; serious injury or illness, considerable damage to property, interruption of operations or considerable financial loss. Inadequate compliance with regulations.
Timescale Codes
1 Matters to which IMMEDIATE attention should be given. Either due to the need for URGENT action, or the SIMPLICITY of completing the recommendation.
2 Matters requiring approval or involving moderate costs. A timescale of THREE TO SIX MONTHS would be appropriate.
3 Matters to which improvements need to be made AS SOON AS PRACTICABLE.
2015.5-B2 Main low voltage switchboard partitioning
A good partioning of the electrical premises will prevent from the spreading of fire. We recommand to install a adequate roof (2h fireproof) to the main low voltage switchboard room. Moreover, the electrical installation will be protected against the dust. The cable opening should be sealed with non-combustible material (plaster for instance).
2015.6-B1 Retention means under oil drums We recommend to place the oil drums under noncombustible containment to prevent the spillage of the combustible liquid.
Main low voltage switchboard
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APPE Artenius PET Packaging Morocco
El Jadida
2015.7-B2 Retention means under machines
As the oil content could be arround 2 000 l for each machine, we recommend to add noncombustible containment arround each machine. The oil is a combustible liquid (flash point : 225°C) and the temperature inside the extruder is 280°C. This measure will prevent the spreading of a potential fire to the other machines.
2015.8-B1 Battery loading in the vicinity of the SX500 machine As the battery charger could be on fire (electricity risk), we recommend to place the battery charger at 2 m away from any combustible material.
2015.9-B3 Install automatic fire detection throughout the plant Although the site is constantly attended by the employees (minimum 2 during the night), we recommend to install an automatic smoke/fire detection system. It will detect earlier an outbreak of fire. The system should cover the whole building and include raw material canopy, transformer room and compressor room.
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APPE Artenius PET Packaging Morocco
El Jadida
C A situation or practice likely to lead to; Minor injury or illness, non-disruptive damage to property and/or moderate financial loss.
Timescale Codes
1 Matters to which IMMEDIATE attention should be given. Either due to the need for URGENT action, or the SIMPLICITY of completing the recommendation.
2 Matters requiring approval or involving moderate costs. A timescale of THREE TO SIX MONTHS would be appropriate.
3 Matters to which improvements need to be made AS SOON AS PRACTICABLE.
No recommendation.
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APPE Artenius PET Packaging Morocco
El Jadida
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APPE Artenius PET Packaging Morocco
El Jadida
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