Note 9: Process safety
Process safety management
Process safety management (PSM) is an integral part of our overall safety strategy. In addition to helping manufacturing sites meet their legal requirements, PSM is an essential first step to operational excellence.
Our PSM framework sets out minimum process safety management standards at all sites and provides a structured way to assess and manage risks to eliminate injuries and incidents related to hazardous substances and processes. Implementation of the framework is phased. Phase A sites are the most safety critical sites, prioritized based on their residual risk, taking into account their inherent safety hazards and current levels of process safety performance.
Process Safety Management program planning
- In 2015, Phase A sites (46) implemented part of their improvement plans according to schedule
- The Phase B sites (82) started the program in 2015, developing their improvement plans for implementation over the next two years
- The remaining 72 sites (Phase C) will carry out the PSM gap analysis in 2016 to develop their improvement plans for implementation by 2018
- PSM is being implemented by line management with the support of PSM experts at all manufacturing sites
- Standard processes for hazard analysis were introduced globally in 2015
- A framework for PSM capability building is being developed to help embed PSM and ensure process safety competence at all our sites
- PSM leading and lagging indicators have been developed and aligned with international best practices to enable effective measurement and monitoring of continuous improvement in PSM. These will be implemented in 2016
Loss of containment
AkzoNobel uses “loss of containment’” as a main indicator of process safety performance at its manufacturing sites.
Loss of containment incidents
We are actively working to reduce our carbon footprint across the value chain – to improve our resource efficiency and reduce our environmental footprint – as well as creating social value by developing our employees and being active in the communities where we operate. And by continuing to innovate in order to supply more sustainable products and solutions for our customers, we create economic, environmental and social value.
- The number of losses of containment classified as Level D remained at zero in 2015 (2014: zero)
- The number of losses of containment classified as Level C decreased to 2 (2014: 9). These spills were reported to the authorities and fully investigated, while immediate action was taken to prevent reoccurrence
- The number of reported Level A minor spills and leaks, which are readily controlled on site, increased by 56 percent to 1,737, illustrating the desire to report, investigate and learn from these process safety near misses. The IRS has proved to be an easy tool to use at site level to manage all incidents, including these minor spills
A loss of containment is an unplanned release of material, product, raw material or energy to the environment (including those resulting from human error). Loss of containment incidents are divided into four categories, dependent on severity, from small, on-site spill up to Level D – a significant escape.
The carbon footprint of a product or organization is the total amount of greenhouse gas (GHG) emissions caused during a defined period, or across the total or part of a product lifecycle. It is expressed in terms of the amount of carbon dioxide equivalents CO2(e) emitted.