gp-04 (2) industrial risk management

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INDUSTRIAL RISK MANAGEMENT

DISCLAIMER

The information contained in this document has been prepared exclusively for internal use by L'Air Liquide S.A. and its affiliates ("Air Liquide"). Since thisdocument is confidential and proprietary to Air Liquide third parties are not entitled to rely on it in any !ay. ith re#ard to third parties Air Liquide does not hold itself out as recommendin# the use of the information contained herein or reliance thereon in any !ay !ithout its prior approval and Air Liquide does not #ive any !arranties on the information contained in this document and assumes no liability or responsibility in connection !ith the information or su##estions hereincontained. Air Liquide ma$es no representations or !arranties as to the completeness of this document and %&SLA&S ALL AA*T&+S +,-+SS &-L&+% &*L/%&*0 1/T *T L&&T+% T T2+ AA*T3 4 +2A*TA1&L&T3 A*% T2+ AA*T3 4 4&T*+SS 4 A -AT&/LA /S+ -/-S+. The present document has been issued in 4rench and in +n#lish.

This document supesedes the !o""o#in$ document%s&'

"P#0$ %1&

Re(ision D)te Pep)ed *+ Appo(ed *+ Ch)n$es

0 1$ 'e(r)ary 2005 *+ristop+e ",-R!. *+ristian P,-*

ee Revision Ta(le

nne 0

, 10 Decem(er 200 *+ristop+e ",-R!. *+ristiane M,33-R

21 May 2010 4anyce D-R-.,O. P+ilippe .DR-.!

.

4

T+is oc)ment is proprietary to t+e !R 3!,!D- "RO,P an m)st not (e comm)nicate to t+ir parties7 !t is one of a set of "ro)p Proce)res t+at8 toget+er8 control t+e 9eyelements affecting safety in ir 3i)ie;s in)strial/meical operations7 !t is not intene for implementa tion inepenently of s)c+ system7 T+is is an )ncontrolle copy7 T+e

only controlle copy is 9ept in t+e leanria ata(ase7




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,2 PURPSE

T+e p)rpose of t+is proce)re is to ientify8 assess an mitigate ris9s relate to +ealt+8 safety8environment an reliability 7

2 RESPNSI/ILIT3

-ac+ subsidiary ana#in# %irector m)st appoint an &ndustrial is$ ana#ement epresentative (&)reporting to +im/+er irectly or to ()siness line management an m)st provie t+e means to carry o)t

t+e mission efine in t+is oc)ment7 T+e & avises t+e Managing Director on in)strial ris9management iss)es an provies tec+nical s)pport to line management in t+e ientification an analysisof in)strial ris9s7

Depening on t+e siEe an compleity of t+e subsidiary;s activities8 more t+an one & may (ere)ire or specialists may (e recr)ite to assist t+e & in ris9 ientification an analysis activities7T+ese in)strial ris9 management specialists s+all report to t+e & 7

T+e & leas t+e implementation an effectiveness of t+is proce)re7 itionally8 & responsi(ilities incl)e:

• -ns)ring t+at ris$ ientification/assessment performe in t+e subsidiary is one wit+ c)rrent

met+oologies8

• -ns)ring t+at people involve in ris$ ientification an assessment +ave (een traine in

!n)strial Ris9 Management met+oologies8

• *onfirming t+at propose mitigation meas)res will re)ce ris9 to a FlowF level %refer to

criticality matrix in "T#PR#*OM 020&8

• Reviewing an approving t+e final ris9 mitigation actions7

T+e & m)st +ave access to all availa(le ata an to t+e facilities wit+in t+e scope of +is/+er mission7

e/s+e s+all not (e part of t+e operations organiEation7

T+e & can an s+o)l propose to t+e subsidiary ana#in# %irector t+at any operation or activity t+atoes not comply wit+ approve in)strial ris9 management r)les or proce)res (e stoppe7 e/s+e s+allfollow )p to ens)re t+at necessary actions esigne to avoi t+e reocc)rrence of s)c+ a sit)ation areimplemente7

.2 CMPETENC3 REUIREMENTS

T+e &ndustrial is$ ana#ement epresentative s+all:

• ave recogniEe tec+nical 9nowlege of ir 3i)ie processes an tec+nologies8






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• ave eperience in esign an/or operations8

• =e 9nowlegea(le in in)strial ris9 management met+oologies8

• ave - 9nowlege8

• ave comm)nication an wor9gro)p teac+ing s9ills7

42 PRCEDURE REUIREMENTS

42,2 INDUSTRIAL RISK MANAGEMENT PRGRAM

T+e & m)st efine an ens)re t+e implementation of an in)strial ris9 management program inaccorance wit+ t+is proce)re7 !n)strial ris9s covere are:

• ealt+ an safety8

• -nvironmental8

• T+ose relate to in)strial systems an pro)cts7

!n)strial ris9 management activities s+all (e etaile (y t+e & in a yearly in)strial ris9management plan covering eisting operations an incl)ing perioic ris$ assessment of operatingfacilities7

*riteria to (e )se to ientify facilities to (e incl)e in t+e ann)al plan are:

• 4acilities w+ere t+e impact of a process relate accident an/or incident co)l +ave severe

conse)ences8

• 4acilities w+ere new or revise manatory reg)lations will apply8

• 4acilities w+ere maGor or rec)rrent accidents an/or incidents or near misses +ave occ)rre8

• Personal eperience7

T+e plans are reviewe (y t+e subsidiary ana#in# %irector assiste (y t+e & at least twice per year7

422 INDUSTRIAL RISK MANAGEMENT PRCESS

T+e steps of t+e in)strial ris9 management process are:






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• Ris9 ientification8

• is$ assessment %severity pro(a(ility&8

• Ris9 mitigation8

• -perience fee(ac97

T+ese steps apply to eisting operations %section $7<& as well as to new pro:ects %section $7$&7

Subsidiaries m)st c+ec9 wit+ t+e S&S %epartment to etermine if generic ris9 st)ies are availa(le for t+e process )ner consieration7 !f s)c+ a st)y is availa(le8 t+e subsidiary m)st )se it as a (asis for t+eir specific st)y7

42.2 RISK ASSESSMENT N E5ISTING 1ACILITIES

Perioic ris$ assessments of eisting facilities m)st (e con)cte (y a team comprise of people epertin in)strial ris9 management met+oology8 people epert in t+e facility ;s tec+nology an processes anrepresentative%s& of Operations7 T+ese st)ies s+all follow t+e process escri(e in $727

42.2,2 RISK IDENTI1ICATIN

T+e process of ris$ identification s+all:

• !ncl)e a compre+ensive review of t+e potential ris9s:

− aEaro)s materials %toicity8 eplosiveness8 corrosiveness8 temperat)reH&8

− Process / tec+nology8

− -)ipment / mac+ine8

− Operational8

− Material compati(ility8

− *ontract)al commitments8

− -nvironmental constraints an impacts8

• =e le (y people +aving goo 9nowlege of:

− T+e process an tec+nology of t+e activity8

− Ris9 ientification met+oologies8

• ,se fee(ac9 information arising from previo)s accidents an/or incidents.






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4.3.2. RISK ASSESSMENT

T+e & s+all ens)re t+at t+e criticality of eac+ ris9 is assesse on t+e (asis of t+e com(ination of Fpro(a(ility of occ)rrenceF an Ft+e severity of potential conse)encesF7

,nesira(le events m)st (e ran9e accoring to t+e criticality matri as efine (y "T#PR#*OM 0207ig+ levels of ris9 %serio)s conse)ences an +ig+ pro(a(ility of occ)rrence& m)st (e re)ce to FlowFlevels (y mitigation meas)res7

*ritical facilities m)st (e re#assesse at intervals no greater t+an 5 years7

42.2.2 RISK MITIGATIN

T+e mitigation meas)res efine (y t+e ris$ assessment s+all (e compare wit+ t+e eisting meas)res7

!f aitional meas)res are neee8 t+ey m)st (e implemente )sing t+e subsidiary MO* proce)re7

T+e subsidiary %)s)ally t+e 4acility ana#er & m)st c+ec9 t+at all mitigation meas)res are implementein t+e facility an:

• !ncorporate in S-

•

*omm)nicate to operators8 tec+nicians an )sers8

• Reg)larly maintaine an teste8

• *an only (e moifie (y )sing t+e subsidiary MO* proce)re7

T+e mitigation meas)res associate wit+ t+e re)ction of ma:or ris$s are calle elements important for safety (+&S)7 ?nowlege of S- relate to +&S s+all (e incl)e in t+e training an qualification program7+&S operating parameters %i7e7 -! set points& can only (e moifie (y personnel )alifie to o so anfollowing oc)mente proce)res7

42.242 E5PERIENCE 1EED/ACK

!n orer to monitor an improve t+e efficiency of its system8 t+e subsidiary s+all implement aneperience fee(ac9 process7

4242 INDUSTRIAL RISK MANAGEMENT IN PR6ECTS

-very pro:ect m)st follow t+e p+ases liste (elow:






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c& -ro:ect Ris9 follow#)p plan

T+e subsidiary s+all esta(lis+ a pro:ect ris9 follow#)p plan for eac+ critical -ro:ect s)mmariEing t+econcl)sions of t+e -A an proviing a means for following#)p t+e completion of mitigation meas)res7

42422 DESIGN AND INITIAL MANU1ACTURING P8ASE

T+e responsi(ility for t+e esign8 initial man)fact)ring an testing of new pro)cts8 e)ipment an/or facilities m)st (e efine7 Detaile ris9 st)ies %2A<- 8 'M-*8 RH& s+all (e con)cte for critical -ro:ects in orer to finaliEe mitigation meas)res7

T+e mitigation meas)res %+&S& for re)cing ma:or ris$ s+all (e efine for all proGects %stanar ancritical& an implemente )ring all t+e p+ases of t+e pro:ect an )ring operation accoring to section$7$7<7 D)ring t+e esign an initial man)fact)ring p+ase8 perioic reviews m)st (e performe to ens)ret+at t+e recommenations of t+e ris9 st)ies are incorporate into t+e esign of t+e installation8e)ipment an/or pro)ct7

T+is also applies to temporary installations7

-ro:ect organiEation missions an responsi(ilities8 perioic esign an man)fact)ring review or in)strialris9 management activities vary epening on t+e nat)re of t+e pro:ect 7

4242.2 CNSTRUCTIN9 COMMISSIONING AND PERATIN P8ASE

D)ring t+is p+ase8 responsi(ilities for implementing an c+ec9ing t+e mitigation actions m)st (e efine7

-ac+ mitigation meas)re m)st (e implemente in operation as escri(e in section $7<7<7 -! m)st (eteste an/or inspecte8 an operational (efore start#)p7 -! m)st (e manage accoring to "P10 an"P11 re)irements7

:2 RECRDS RETENTIN

T+e following s+all (e retaine for at least 10 years after t+e close of t+e facility an/or t+e en of t+ecommercial life of t+e pro)ct:

• T+e proGect ris9 ientification8

• T+e preliminary ris9 analysis8

• Design stage ris9 st)y reports8

• 4acility ris9 review reports8

•

Recors of completion of ris9 mitigation actions7






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;2 AUDIT C8ECK-LIST

T+e implementation of t+is proce)re s+all (e a)ite7 T+e a)it fre)ency s+all (e efine (y t+e hief &ndustrial Auditor 7

T+e a)it form in nne 1 may (e )se for g)iance7






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ANNE5 0 < RE7ISIN TA/LE

Re(isionIndic)te the modi!ied section num*es

)nd po(ide ) shot desciption o! the ch)n$es

,

ection 2 J!.#*?#*OM#005K replace (y J"T#PR#*OM#020K

ection $72 J()sinessK replace (y JoperationsK

ection $7<7 T+e first sentence +as (een (roaene7

ection $7<71 JT+e process of proGect ris9 ientification s+all:K replace (y JT+e process of ris9ientification s+all:K

ection $7<71 3ast sentence was elete

ection $7<72 L+ole section rewore

ection $7<7< e Jan following oc)mente proce)res7K

ection $7<7<7 !n t+e (rac9ets of t+e last sentence F-!F +as (een ae (efore Fset pointsF7

ection $7<7< 3ast sentence relate to t+e former ris9 management oc)mentation was elete

ection $7$71 JT+e s)(siiary RMRK replace (y JT+e RMR of t+e s)(siiary owning t+e proGectK

ection $7$71 3ast sentence relate to t+e former ris9 management oc)mentation was elete

ection $7$72 e Jfor all proGects %stanar an critical&K

ection $7$72 3ast sentence relate to t+e former ris9 management oc)mentation was elete

ection $7$7< L+ole section rewore7 e J-! m)st (e teste an/or inspecte8 anoperational (efore operationK

ection 5 Retention time c+ange to 10 years after t+e close of t+e facility an/or t+e en of t+ecommercial life of t+e pro)ct

ection B ection elete

nne 1 apte to revise tet of "P

nne 2 e JPotential environmental impactK at t+e en of n 1

nne 2 e Jfor t+e s)(siiaryK in t+e 2n line of n $

nne < Title c+ange to J-ample of Preliminary Ris9 nalysis 'ormK an c+ange forms

nne $ nne elete

Jris9 managementK +as (een c+ange to Jin)strial ris9 managementK t+ro)g+o)t t+e oc)ment

.

4






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ANNE5 , < AUDIT C8ECKLIST

T+e p)rpose of t+is a)it c+ec9list is to g)ie t+e "ro)p !n)strial )itor in +is/+er preparation of protocols for a)iting compliance of s)(siiary in)strial management systems wit+ "ro)p re)irements7 !t can also (e )se (y s)(siiaries to self#a)it s)c+ compliance7 !tis not intene for )se (y s)(siiaries to a)it compliance of t+eir facilities wit+ t+eir s)(siiary in)strial management systems7

Subsidiary /entity: NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

Date: NNNNNNNNNNNNNNNNNNNNNN

)itors: NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

!nterviewees: NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

Re=uiements 1indin$s Comments

Section - Responsi*i"it+

17 n & +as (een appointe7 > .

27 T+e & reports irectly to t+esubsidiary ana#in# %irector or to t+e()siness line Managers7

> .

<7 Go( profile for t+e & consistentwit+ t+e responsi(ilities liste in section 2is in place7

> .

$7 T+e & is not part of t+e operationsorganiEation7

> .

Section . < Competenc+ Re=uiements

17 T+e s9ills8 eperience ancompetencies of t+e & are consistent

wit+ t+e re)irements of section <7

> .

Section 42, < Ris> M)n)$ementPo$)m

17 n in)strial ris9 management program+as (een clearly efine animplemente7

> .

27 n ann)al in)strial ris9 managementplan efining ris$ assessment for eistinginstallations is in place7

> .






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<7 T+e criteria liste in section $71 +ave(een )se to select facilities for incl)sionin t+e ann)al plan7

> .

$7 T+e ana#in# %irector +as reviewet+e ann)al plans at least twice per year7

> .

Section 42 < Industi)" Ris> M)n)$ement Pocess

17 T+e subsidiary;s in)strial ris9management process incorporates t+ere)irements of section $727

> .

Section 42.2 < Risk Assessment o! E?istin$ 1)ci"ities

17 Perioic ris$ assessments of eistingfacilities are ta9ing place7

> .

27 ris9 ientification proce)reincorporating t+e re)irements of section

$7<71 is in place7

> .

<7 ris$ assessment proce)reincorporating t+e re)irements of section$7<72 is in place7

> .

$7 itional mitigation meas)resientifie (y is$ assessments areimplemente )sing t+e MO* proce)re7

> .

57 Mitigation meas)res are implemente8comm)nicate to operators an

incorporate in OPs7

> .

67 -lement !mportant for afety areincl)e in t+e training an )alificationprogram

B7 process an proce)res for feeing(ac9 eperience from t+e in)strial ris9management process is in place7

> .






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Section 424 < Ris> M)n)$ement in Project

17 -ro:ect ris$ identification +as (eenone for every pro:ect )ring t+e pro:ect evelopment p+ase7

> .

27 T+e & is re)ire to classify all pro:ects as escri(e in section $7$71

> .

<7 Recors of all pro:ect classificationsare maintaine7 T+e S&S %epartment iscopie for critical -ro:ects7

> .

$7 preliminary ris$ analysis +as (eenone for every critical pro:ect an resi)alris9s ientifie7

> .

57 ris9 follow#)p plan +as (een preparean implemente for every critical pro:ect.

> .

Section 4242 < Desi$n )nd Initi)" M)nu!)ctuin$ Ph)se

17 +&S (+lements &mportant for Safety)+ave (een ientifie7

> .

27 Perioic reviews are performe )ringesign an initial man)fact)ring to ens)ret+at recommenations of ris9 st)ies areincorporate7

> .

Section 4242. < Constuction9 Commissionin$ )nd pe)tion Ph)se

17 Responsi(ilities for implementing anc+ec9ing mitigation actions are efine7

> .

27 -ac+ mitigation meas)re isimplemente in operation7

> .

Section : < Recods Retention

17 3iste recors are retaine for t+eperio of time re)ire in t+is section7

> .






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ANNE5 ' E5AMPLE 1 PROJECT RISK IDENTIICATION 1RM

GP-04 (2) - Annex 2

- PRI.doc






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ANNE5 . ' E5AMPLE 1 PRE!IMINAR" RISK ANA!"SIS 1RM



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