1. Filename GPCA Responsible Care Workshop Process Safety Standard & Practices GPCA Responsible Care Workshop

2. 1 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop Faisal Malallah…….. Team Leader Faisal Malallah…….. Team Leader Faisal Malallah…….. Team Leader Vijay Kumar………... EQUATE Vijay Kumar………... EQUATE Vijay Kumar………... EQUATE Tariq Alauddin………Sipchem Tariq Alauddin………Sipchem Tariq Alauddin………Sipchem Yunus Qasim……….. Sabic Yunus Qasim……….. Sabic Yunus Qasim……….. Sabic Andrew Blue………... LR Energies Andrew Blue………... LR Energies Andrew Blue………... LR Energies Team Team Team

3. 2 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop Agenda Agenda Agenda  Introduction  Introduction  Introduction  Development of Code  Development of Code  Development of Code  Process Safety Management  Process Safety Management  Process Safety Management  Management Practice  Management Practice  Management Practice  Guidance/ Examples  Guidance/ Examples  Guidance/ Examples

4. 3 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop Introduction Introduction Introduction  Process Safety Management (PSM) is the application of management principles and systems for identification, understanding and control of process hazards to prevent process-related injuries and accidents.  The code has 12 management practices  The code discusses guidance, examples and self assessment notes.

5. 4 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop Development of code Development of code Development of code Team was formed by the GPCA Responsible Care committee. Team members shared their process safety management standards and implementation strategies. Aligned with CCPS(Center of Chemical Process Safety).

6. 5 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop Development of code Development of code Development of code Team discussed each and every requirement and how their respective industries are complying. Considered industrial development in the region while developing code. Listed out examples for better understanding.

7. 6 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice: PS-1 Management Practice: PS-1 Management Practice: PS-1 Leadership by senior management through policy, goal setting, participation, communications and resource commitments in achieving continuous improvement of performance. Process Safety Near Miss other inciden ts PSI

8. 7 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation EQUATE has vision and values statement and commitment from management. These are documented in EH&S Policies and procedures, that are approved by VP operations. Management Practice PS-1: Examples Management Practice PS-1: Examples Management Practice PS-1: Examples Implementation of PSM at EQUATE:

9. 8 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation VP operations and CEO conduct site visits Follow ODMS(Operating Discipline Management System). This has 10 sections and section 6.08 is process safety. Management Practice PS-1: Examples Management Practice PS-1: Examples Management Practice PS-1: Examples Implementation of PSM at EQUATE:

10. 9 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice: PS-2 Management Practice: PS-2 Management Practice: PS-2 Current, complete documentation of process design, operating parameters and procedures and information relating to the hazards of material and process technology should be maintained and readily available.

11. 10 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation EQUATE follows IVPP and EDMS system for documentation of engineering drawings and Procedures. All PIDs, PFDs, PDS, MSDS plant layouts etc., documentation is saved electronically. Management Practice PS-2: Examples Management Practice PS-2: Examples Management Practice PS-2: Examples Implementation of PSM at EQUATE:

12. 11 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Procedures mention safe operating conditions and their operating limits and immediate actions required by Operators in case of alarms. Procedures are available electronically Management Practice PS-2: Examples Management Practice PS-2: Examples Management Practice PS-2: Examples Implementation of PSM at EQUATE:

13. 12 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice: PS-3 Management Practice: PS-3 Management Practice: PS-3 Consideration and mitigation should be given to the potential of safety effects during design, construction and start up phases of expansions, modifications and new facilities, utilizing established engineering practices consistent with recognized codes and standards.

14. 13 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Process Hazard Facility siting Plot plans Process Design and review procedures Project management procedures and controls Management Practice : PS-3 Management Practice : PS-3 Management Practice : PS-3 The reviews should include but not limited to:

15. 14 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Management Practice PS-3 : Examples Management Practice PS-3 : Examples Management Practice PS-3 : Examples EQUATE uses LPP(Loss Prevention Principles) and Process Risk Management Standard(PRMS)  4 levels of Risk analysis  RCPHA, LOPA target Factors, CEI/FEI calculations are level 1 PSM Implementation PSM Implementation PSM Implementation

16. 15 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop Management Practice PS-3 : Examples Management Practice PS-3 : Examples Management Practice PS-3 : Examples  Level 2 is complete LOPA and risk analysis for CEI/FEI higher than threshold  Level 3 Enhanced risk review(if LOPA gaps exists)  Level 4 is QRA PSM Implementation PSM Implementation PSM Implementation

17. 16 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-4 Management Practice : PS-4 Management Practice : PS-4 Periodic assessment and documentation of process hazards and implementation of actions and credible emergency procedures to minimize risks associated with chemical operations, including the possibility of human error should be established.

18. 17 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Management Practice PS-4 : Examples Management Practice PS-4 : Examples Management Practice PS-4 : Examples At EQUATE  Every 3 years revalidation of RCPHA for existing facilities  Every 5 years revalidation of LOPA PSM Implementation PSM Implementation PSM Implementation

19. 18 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop Management Practice PS-4 : Examples Management Practice PS-4 : Examples Management Practice PS-4 : Examples  LPP gap assessment for all retrofits requirements during RCPHA cycle  Review of CEI and FEI during RCPHA  Emergency response plans reviewed during RCPHA cycle PSM Implementation PSM Implementation PSM Implementation

20. 19 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-5 Management Practice : PS-5 Management Practice : PS-5 A process of safety reviews on all new and modified facilities during design and prior to start up.

21. 20 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Management Practice PS-5 : Examples Management Practice PS-5 : Examples Management Practice PS-5 : Examples At EQUATE  PSSR(Pre Start up Safety Review) for new and modified facilities  Punch listing line by line and equipment  FIE(Functional Input and Evaluation) checklist is completed. PSM Implementation PSM Implementation PSM Implementation

22. 21 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Management Practice PS-5 : Examples Management Practice PS-5 : Examples Management Practice PS-5 : Examples  Operating/ Start up and shutdown procedures are reviewed every 3 year cycle or whenever changes occurs.  Actions from all reviews are tracked by AITS. PSM Implementation PSM Implementation PSM Implementation

23. 22 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-6 Management Practice : PS-6 Management Practice : PS-6 Management of changes to chemical operations to maintain or enhance the original safety case designed into facility. PSV

24. 23 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Management of Change EQUATE has a well developed web based management of change tool. The tool is developed in house. Management Practice PS-6 : Examples Management Practice PS-6 : Examples Management Practice PS-6 : Examples PSM Implementation PSM Implementation PSM Implementation

25. 24 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-7 Management Practice : PS-7 Management Practice : PS-7 Documented maintenance and inspection programs that insure facility integrity is effective.

26. 25 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation PS-7: Equipment Integrity PS-7: Equipment Integrity PS-7: Equipment Integrity Design and installations Equipment tests and inspections, including predictive and preventative maintenance Maintenance procedures Quality control

27. 26 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Management Practice PS-7 : Examples Management Practice PS-7 : Examples Management Practice PS-7 : Examples At EQUATE  GMISS(Global Mechanical Integrity Safety Standard) is followed.  This includes registration of hazardous equipment and identifying inspection intervals.  Risk Based Inspections(RBI) is conducted  All inspection records are maintained in SAP PSM Implementation PSM Implementation PSM Implementation

28. 27 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-8 Management Practice : PS-8 Management Practice : PS-8 Establishment of procedures and work practices that ensure safe operation and maintenance of facilities. Individual Barrier manage human interaction operating proceduresoperating procedures process alarmsprocess alarms emergency response Emergency proceduresEmergency procedures

29. 28 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Implementing PS & RM Programs Implementing PS & RM Programs Implementing PS & RM Programs Management Practice PS-8 : Examples Management Practice PS-8 : Examples Management Practice PS-8 : Examples At EQUATE  A procedure use policy exists, mentions on identifying hazards and their controls plan, classifying procedures and review and training requirements.  All operators are trained on job specific procedures prior to their start of work.

30. 29 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-9 Management Practice : PS-9 Management Practice : PS-9 Identification of skills, knowledge and competencies necessary for the employees to maintain proficiency in safe work practices associated with safety critical activities.

31. 30 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Implementing PS & RM Programs Implementing PS & RM Programs Implementing PS & RM Programs  EQUATE has a well documented training system, both online and classroom trainings are conducted  Employees and contractors included, EH&S and job specific training provided  Training identified through a training matrix Management Practice PS-9 : Examples Management Practice PS-9 : Examples Management Practice PS-9 : Examples

32. 31 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-10 Management Practice : PS-10 Management Practice : PS-10 Investigation, reporting, appropriate corrective action and effective sharing of lessons to identified stakeholders of each incident which resulted or could have resulted in a serious process safety incident.

33. 32 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Implementing PS & RM Programs Implementing PS & RM Programs Implementing PS & RM Programs  A web based AICR tool exists.  EH&S incidents investigated independently by EH&S functions  AICR investigation presented to all Production leaders  Lessons Leveraged to other departments Management Practice PS-10 : Examples Management Practice PS-10 : Examples Management Practice PS-10 : Examples

34. 33 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-11 Management Practice : PS-11 Management Practice : PS-11 Measurement of performance, audits for compliance and implementation of corrective actions to be established.

35. 34 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Implementing PS & RM Programs Implementing PS & RM Programs Implementing PS & RM Programs  A well established auditing program both internal and external  Internal by EH&S expertise center  External every 3-5 years by a team of Dow expertise(8-10 auditors) for 15 days Management Practice PS-11 : Examples Management Practice PS-11 : Examples Management Practice PS-11 : Examples

36. 35 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence PSM Implementation PSM Implementation PSM Implementation Management Practice : PS-12 Management Practice : PS-12 Management Practice : PS-12 Establish a learning culture of process safety information and knowledge from both internal sources and through established networks.

37. 36 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Achieving operating excellence Achieving operating excellence Achieving operating excellence EQUATE sends employees for training at conferences outside and at Dow sites for training and learning new developments. Global Process safety expertise meet at Dow site once a year for sharing their learnings. Management Practice PS-12 : Examples Management Practice PS-12 : Examples Management Practice PS-12 : Examples

38. 37 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop EH&S Excellence Achieving operating excellence Achieving operating excellence Achieving operating excellence Incident Rate Incident Rate Incident Rate Business growth Business growth Business growth A well implemented PSM program A well implemented PSM program A well implemented PSM program

39. 38 GPCA Restricted - For Internal Use Only GPCA Responsible Care Workshop