Definition

Indicators monitored for Process Safety Management System are aligned with OSHA (United States Occupational Safety and Health Administration) definitions. Indicators used to monitor Process Incidents (PSI) are aligned with International Council of Chemical Associations (ICCA) standards. Reported process incidents with environmental consequences are monitored and classified according to defined criteria: quantity of spilled material, consequences on site or off site, damage to the immediate vicinity, fish kills, and severity (medium, high, and catastrophic). The overall management of historical soil contamination can be monitored via the many environmental provisions.

Management approach

Solvay’s approach to preventing process incidents is based on the 14 OSHA items of Process Safety Management System, with special attention paid to Process Hazard Analysis. Risk analysis forms the backbone of risk control. This risk analysis covers existing, new, or modified installations. Quantified risk analysis is a best practice among industrial companies: standardized risk analysis makes it possible to quantify the risk level of every possible accident scenario, combining severity and probability factors.

The incident rate (PSI rate) is monitored and benchmarked with peers. Each incident is analyzed according to ICCA standards (International Council of Chemical Associations) and corrective actions are taken, with a focus on incidents with operating permit exceedance.

The corporate “Environmental Rehabilitation” department is dedicated to overseeing the management of closed sites and addressing environmental liabilities resulting from historical soil contamination at all concerned sites. An Enterprise Risk Management approach is followed, backed by clear governance that combines a local approach (team management) with a global team (through initiatives). The aim is to significantly reduce Solvay’s environmental liabilities and obligations and to effectively address and remediate environmental liabilities on operating sites.

Indicators

Risk analysis program

Solvay’s objective:

2020

100%

of product lines having a risk analysis updated in the past five years

Risk analysis of production lines

In %

 

2018

 

2017

Scope: the consolidated data for process safety risk analysis covers 131 sites out of a total about 152 operational sites including Research and Innovation centers with significant chemical process risks – excluding mines, careers, and laboratories with lower risks.

Product lines having a risk analysis updated in the past five years

 

85

 

77

The risk analysis program makes it possible to identify major accident scenarios and take the necessary preventive measures to control the level of risk and keep it acceptable. Solvay uses tiered risk analysis methods and adapts them to the level of potential hazard of every process at every Global Business Unit. The increase reflects the deployment of the assessment program started in 2015 and to be achieved by 2020. In 2016 and 2017, most of the progress was due to the deployment of the simplified method – called PRAMAPOR – for material and processes with low potential hazards.

Process incidents

Process incidents classified according to severity

 

 

2018

 

2017

(*)

Process incidents with environmental consequences are being monitored and classified according to several criteria: quantity of material spilled, consequences on site or off site, damage to the immediate vicinity, fish kills, and severity (medium, high, and catastrophic).

(**)

Number of process Incidents per 100 full time employee (employees and contractors, assuming 2,000 hours of work/worker/year): Solvay’s process incident rate (PSI rate) is consistent with the method proposed by the International Council of Chemical Associations (ICCA).

Scope: the consolidated data for process safety incidents covers 107 sites out of a total about 153 operational sites including Research and Innovation centers with significant chemical process risks – excluding mines, careers, and laboratories with lower risks.

High-severity process incidents with environmental consequence (*)

 

0

 

0

Medium-severity process incidents with environmental consequences (*)

 

47

 

59

… with operating permit exceedance

 

12

 

27

… without permit exceedance

 

35

 

32

Process safety incident rate (**)

 

1

 

0.9

No high incidents with environmental consequences, or catastrophic-severity incidents were reported for 2018, meaning there was no accidental event with long-term damage off site for the environment. Solvay’s target is to avoid any high severity incident and to reduce the incident rate for medium severity incidents. In 2018, 47 incidents with environmental consequences were reported and, among those, 12 processes were associated with releases above operating limits. The Group has followed up on each incident to ensure adequate actions are taken to avoid recurrence.

The indicators Process Safety Management System (PSM) relative to the implementation of management system consistent with the Solvay Cares Management System (SCMS) is not consolidated at Group level anymore. Sites may now implement safety management system using other references than SCMS and in particular OSHA 18001, ISO 14001, etc. The internal control procedures based on the Solvay Cares Mangement System are no more effective as of 2018.