Transcript sipchem_gpca_metrics_presentation_rev01
Responsible Care Performance Metrics
Kashif Rasheed Senior Consultant Lloyd’s Register EMEA 24 September 2012
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Responsible Care Performance, Metrics Definitions, Data Analysis, Results and Q&A
• Background • Guidance Document Overview and EH&S Performance Measurement Categories • Scope of data received and analyzed • Value of Metrics, Definitions and Data set analysis by Category • Summary
Background
• Lloyd’s Register being a third party and having extensive experience in independent assurance reviews, was assigned with responsibility to gather, analyze and benchmark this data for today’s workshop.
• Lloyd’s Register was provided data without companies identification.
• LR Team worked with the RC Metrics sub-committee to develop the contents of this workshop.
• All data inputs provided by GPCA member companies are treated without any modifications/corrections.
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Guidance Document Overview and EH&S Performance Measurement Categories
• Content of Guidance Document: • Metric Value • • • Units of the Metric Definitions Member Reporting Instructions • 5 Categories (21 Indicators) • • Occupational Safety (6) Process Safety(3) • • • Emissions / Discharges to Environment (8) Resource Utilization (3) Distribution Incidents (1)
5 GPCA Metrics Current Template GPCA Company Name: Report for the Year:
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C.
1 2 3 4 5 6 7 8
S.No
A.
1 2 3 4 5 6
B.
1 2
Metric Name Occupational Safety
Employee Fatalities Lost Time Injury Incident rate for Employees OSHA Recordable Cases Incidence Rate for Employees Contractor Employee Fatalities Lost Time Injury Incidence Rate for Contract Employees
Process Safety
Process Safety Incidents Process Safety Total Incident Rate (PSTIR)
Metric Formula / Definition
# of Fatalities (# of days away from work cases X 200,000) / Employee man-hours worked (# of Injuries X 200,000) / Employee man-hours worked # of Fatalities (# of Injuries X 200,000) / Contractor man-hours worked (# of Incidents that meet the Process safety Incident Criteria (# of Process Safety Incidents x 200,000) / (Employee + Contractor Employee man-hours) (Total Severity Score x 200,000) / (Employee + Contractor employee man-hours) Process Safety Total Incident Severity Rate (PSTIR)
Emissions / Discharges to Environment
Hazardous Waste for Disposal Non-Hazardous Waste for Disposal Quantity of Waster Water discharged to Environment Discharges to Water - Chemical Oxygen Demand Sulfur Dioxide Nitrogen Oxides (NOX) Total Green House Gas Emissions (GHG) Carbon Dioxide (CO 2 ) Intensity Metric tons / Year Metric tons / Year Cubic Meters / Year Metric tons of O2 / Year Metric tons / Year Metric tons / Year Metric tons CO 2 Equivalent (See Appendix C & D & E) Million Metric tons emitted per year / Million Metric tons of production
D.
1 2 3
E.
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Resource Utilization
Use of Energy (Tons of Fuel oil Equivilant; TOE) Specific Energy Consumption Process Water Consumption
Product Distribution
No of Distribution Incidents Energy from Fossil Fuels + Net Energy Purchased + Self Generated Renewable Energy TOE / Metric tons of production Millions of Cubic Meters Total # of Incidents classified by means of transport Phase I - 2010 Data to be reported by September 2011 Phase II - 2011 Data to be reported by March 2012 Phase III - 2012 Data to be reported by March 2013 Phase IV - Potential Metric for 2014
GPCA Member Company Annual Report
Gulf Petrochemicals & Chemicals Association-GPCA GPCA Members-Performance Metrics-Consolidated
Performance Metrics - 2010
Metric Name
Assigned PM Key
Full Members
M-02 M-03 M-04 M-05 M-06 M-07 M-08 M-10 M-11 M-13 M-16 M-17 M-18 M-19 M-20 M-21 M-23 M-25 M-26
Total
6 M-29
Legend: NR - NOT REPORTED
A1
0 0 0 0 0 0 0 0 0 0 0 0 NR 1 0 0 0 0.0
0 0
A2
0.08
0 0.705
6.07
0 0 2.45
0.036
0 0.22
0 0 0 0.20
6.03
0 0.00
0.0
0 0
A3
0.41
0 1.41
0.21
0 0 0.22
0.14
0 1.16
0.42
0.32
0.28
0.26
0.26
0.07
0.00
0.0
0 0.2086
A4
0 0 0 0 0 0 0 0 0 0 0 0 NR 4 0 0 0 0.0
0 0
B1
0 0 NR 0 2 0 NR 0 15 0 NR NR 0 8 NR NR NR NR 0 0
B2
0 0 NR 0 0.42
0 NR 0 0.08
NR NR NR 0 0.15
NR NR NR NR 0 0
C1
20,840 15.98
0 140 91 301.7
110.28
223.388
342 143.43
227 142,122 1,308 377,544 34,667 4,919 576 18654 1460 748 603,856
C2
453 31.20
592 120 250 206.6
28 139.008
656 445.4
62 6,188 616 100,289 222.5
1,802 268 0.0
0 888 112,989
C3
0 76,530.50
128,604 109,000 526,220 334,103,112 642,204 1,473,660 912,300,856 1,270,200 NR 2,086,555 47,249 5,892,925 0 0 0 0 0 380,454,181.5
1,639,111,297
C4
0 NR NR 1.7
7.48
20,046.2
NR 177 79 29.72
152 156.5
NR 133,360 0 0 0 0.0
13.92
0 154,023
D3
3.03
0.18
1.7073
0.331
0.684
1.606
1.15
4.46
2.87
2.08664
1,116,216 4.37
1.09
44.37
7.2
7.44
1.53
1.53
0.69
8,423.6
1,124,726
Comments
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2010 EH&S Data Received Phase I Submittals
50 40 30 20 10 0 90 80 70 60 80
97.5%
78 Occupational safety (6) 20 / 24 companies participated
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Required Reported 40
57.5%
23 Process Safety (3) 80
93.75%
75 Emissions/Discharges (6)
120 100 80 60 40 20 0 114
100 %
114 Occupational safety (6) 19 / 24 companies participated
9 2011 EH&S Data Received Phase II Submittals
Required Reported 57
80.7%
46 Process Safety (3)
93.8%
114 107 57
96.5%
55 Emissions/Discharges (6) Resource Utilization (3)
400 350 300 250 200 150 100 50 0
10 2010/2011 EH&S Data Received
Required Reported 200
88 %
176
94 %
342 322 2010 Phase I 2011 Phase II
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Occupational Safety
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Value of Occupational Safety Metrics
• They are important to stakeholders.
• They are measures of the most severe and significant safety factors.
• They are proven safety metrics, universally used.
• They can be used as a basis to demonstrate performance improvement.
• They have high benchmarking value
Occupational Safety Definitions
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Employee Fatalities:
Death, regardless of the time between injury or exposure and death or length of the illness, caused by a work-related event or exposure •
Recordable Injury Incident Rate
: Defined as the number of OSHA recordable incidents for each 100 full-time employees per year based on 2,000 hours worked per employee per year.
Annual # of Recordable Injury Cases x 200,000 employee hours Annual number of employee hours worked •
Lost Time Injury Incident Rate:
Defined as the number of lost workday Injury incidents for each 100 full-time employees per year, based on 2,000 hours worked per employee per year Annual # of Days Away from Work Cases x 200,000 employee hours Annual number of employee hours worked
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GPCA Member Company, Occupational Safety Data Set Analysis
(TRIR=Total Recordable Incident Rate)
Arithmetic AVG.* = 0.27
7 Reporting Zero Actual AVG. TRIR = 0.17
Arithmetic AVG. * = 0.426
*TRIR AVG. derived from taking actual average instead of using incidents and man-hours Key Messages: TRIR low for most companies and 35% report a “zero” incident rate 14
GPCA Member Company, Occupational Safety Data Set Analysis
(TRIR=Total Recordable Incident Rate)
2011 TRIR for Contractor Employees
TRIR AVG.* 0.34
7 Reporting Zero *TRIR AVG. derived from taking arithmetic average instead of using incidents and man-hours Key Messages: TRIR low for most companies and 37% report a “zero” incident rate 15
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2010 and 2011 Occupational Safety Performance Benchmarks
2010-2011 Key Messages - Occupational Safety
• Actual number of injuries and man-hours worked are needed to calculate GPCA overall TRIR • In 2010 88% of the data requested for this category was received from 83% of member companies ( 20 out of 24) • In 2011 100% of the data requested for this category was received from 79% of member companies ( 19 out of 24) • A large percentage of GPCA companies report a zero incident rate.
• Some inconsistencies in data set indicate a need for uniform understanding of definitions (22 LTIs & 6 Recordables, 10 LTIs and 4 Recordables)
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Occupational Safety Panel Q&A
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Process Safety
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Process Safety – Value of Metrics
• Are important to stakeholders • Provide a measure to benchmark across industry • Demonstrates performance improvements
Process Safety Incident
An unplanned or uncontrolled release of any material, from a process that results in one or more of the consequences listed below: 1.
2.
3.
4.
An employee or contractor LTI, and/or fatality, or hospital admission and/or fatality of a third party (non-employees/contractor).
An officially declared community evacuation or community shelter-in-place; Fires or explosions resulting in greater than or equal to $25,000 of direct cost to the company, or; An acute release of flammable, combustible, or toxic chemicals greater than the chemical release threshold quantities
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Process Safety Definitions ……Cont.
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Process Safety Incident Count (PSIC):
The count of all incidents which meet the definitions of a Process Safety Incident.
•
Process Safety Total Incident Rate (PSTIR):
The cumulative (annual) count of PSI normalized by man-hours.
Number of PSI in a year x 200,000 Total Man-hours Employees & Contract Employees •
Process Safety Incident Severity Rate (PSISR):
The cumulative (annual) severity weighted rate of Process Safety Incidents PSI normalized by man-hours.
Total Severity Score for all PSI in a year x 200,000 Total Man-hours Employees & Contract Employees
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What Is Severity Level?
23 Consequences of PSI Incident
Recordable Injury to Employee or Contractor Lost Word Day ( Lost Time) Injury Fire or explosion resulting in direct cost 100,00 to 1 Million $ On Site Fatality employee or contractor Fire or explosion resulting in direct cost > 10 million $
Severity Level from CCPS Table 2
2 1 4 3 3
GPCA Member Company, Process Safety Data Set Analysis Not Reported : 8 9 reporting zero 25 10 5 20 15
2011 Number of Process Safety Incidents
Not Reported: 3 9 reported zero 0 0 2 4 6 8 10 12 14 16 18 24 Key Messages: Wide variance in numbers reported indicate understanding needed on definitions & Data capturing. 20
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2010-2011 Key Messages Process Safety
• Data not sufficient to establish trends or use as benchmarks.
• Additional data sets to be requested to make meaningful comparisons.
• Members to review their internal systems for data capturing/recording.
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Process Safety Panel Q&A
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Environmental Emissions/Discharges
Emissions and Discharges
Value of Metrics:
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Hazardous and Non Hazardous Waste for Disposal:
efficient use of resources primarily a measure for the •
Discharge to Water - Quantity & Chemical Oxygen Demand:
adverse impact on the aquatic environment reflects the potential •
Sulphur Oxides (SOx) and Nitrogen Oxides (NOx):
the Responsible Care Global Charter.
This core measure is identified in • • It is important to external stakeholders and relatively easy for members to report.
It is a regulatory requirement in most areas.
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•
Discharge to Water - Quantity & Chemical Oxygen Demand (COD):
Waste water discharged to the environment directly or through a third party water treatment facility and the amount of COD in the discharged waste water.
•
Sulphur Oxides (SOx) and Nitrogen Oxides (NOx):
Annual emissions inventory for criteria pollutants, NOx and SOx, for those company sources within facilities that are required to prepare and submit annual emissions inventory as per their respective permitting / regulatory requirements
Environmental Data Reporting – 2010 & 11
Environmental Data Rquired
120 100 80 60 40 20 0 80 2010
Reported Data inputs by GPCA Members
85 % 68 114 30 2011 82 % 94
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Emissions and Discharges Key Messages
• In 2010 94% of the data requested for this category was received from 83% of member companies ( 20 out of 24!) • In 2011 94 % of the data requested for this category was received from 79% of member companies ( 19 out of 24!) • Extreme variations in submitted data – possible need for understanding of metric definitions.
• Data quality/quantity not sufficient for benchmarking
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Environmental Emissions & Discharges Panel Q&A
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Resource Utilization
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Resource Utilization
Value of Metric:
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Energy Efficiency:
It is an important measure for global stakeholders.
• It is also tracked by many other reporting tools and systems.
• This speaks to sustainability issues.
•
Process Water Consumption
This ICCA core measure is identified in the Responsible Care Global Charter.
• • This is important to external stakeholders.
It is also a clear new generation metric.
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Resource Utilization Definitions
Use of Energy (Tons of Fuel oil Equivalent; TOE)
Total energy consumed at GPCA member company facilities. • This includes purchased non feedstock power and energy from combustion of waste or by product streams.
• • Energy recovered from the process is not considered as consumed energy.
Detailed calculation methodology is attached to the guidance document
Process Water Consumption :
The total amount of water pumped, piped, or otherwise brought on site for use in manufacturing activities and not returned to the water source from which it was withdrawn.
Resource Utilization - Data Set Analysis 60 50 40 30 20 10 0
Data Inputs Required
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Data Inputs Reported
100 % 20 57 94.7 % 54 2010 2011
Key Message: Data Sets with huge variations demands a better understanding of metrics definitions.
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Resource Utilization Panel Q&A
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Summary
• Quantity of Data inputs received are encouraging • Analysis identifies the need for a better and uniform understanding of the metrics definitions • Use this workshop to share and learn from each other • Contractors engagement for this campaign is essential.