Responsible Care Performance
Metrics
Kashif Rasheed
Senior Consultant
Lloyd’s Register EMEA
24 September 2012
Responsible Care Performance, Metrics Definitions, Data Analysis,
Results and Q&A
2
•
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.
3
Guidance Document Overview and EH&S Performance Measurement Categories
•
•
4
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)
GPCA Metrics Current Template
GPCA Company Name:
S.No
Report for the Year:
Metric Name
A.
Occupational Safety
1
Employee Fatalities
# of Fatalities
2
Lost Time Injury Incident rate for Employees
(# of days away from work cases X 200,000) / Employee man-hours worked
3
OSHA Recordable Cases Incidence Rate for Employees
(# of Injuries X 200,000) / Employee man-hours worked
4
Contractor Employee Fatalities
# of Fatalities
5
Lost Time Injury Incidence Rate for Contract Employees
(# of Injuries X 200,000) / Contractor man-hours worked
6
OSHA Recordable Cases Incidence Rate for Contract Employees
(# of Injuries X 200,000) / Contractor man-hours worked
B.
Process Safety
1
Process Safety Incidents
(# of Incidents that meet the Process safety Incident Criteria
2
Process Safety Total Incident Rate (PSTIR)
(# of Process Safety Incidents x 200,000) / (Employee + Contractor Employee man-hours)
3
Process Safety Total Incident Severity Rate (PSTIR)
(Total Severity Score x 200,000) / (Employee + Contractor
employee man-hours)
C.
Emissions / Discharges to Environment
1
Hazardous Waste for Disposal
Metric tons / Year
2
Non-Hazardous Waste for Disposal
Metric tons / Year
3
Quantity of Waster Water discharged to Environment
Cubic Meters / Year
4
Discharges to Water - Chemical Oxygen Demand
Metric tons of O2 / Year
5
Sulfur Dioxide
Metric tons / Year
6
Nitrogen Oxides (NOX)
Metric tons / Year
7
Total Green House Gas Emissions (GHG)
Metric tons CO2 Equivalent (See Appendix C & D & E)
8
Carbon Dioxide (CO 2) Intensity
Million Metric tons emitted per year / Million Metric tons of production
D.
Resource Utilization
1
Use of Energy (Tons of Fuel oil Equivilant; TOE)
Energy from Fossil Fuels + Net Energy Purchased + Self Generated Renewable Energy
2
Specific Energy Consumption
TOE / Metric tons of production
3
Process Water Consumption
Millions of Cubic Meters
E.
Product Distribution
1
No of Distribution Incidents
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
5
Metric Formula / Definition
Total # of Incidents classified by means of transport
GPCA Member Company
Annual Report
Gulf Petrochemicals & Chemicals Association-GPCA
GPCA Members-Performance Metrics-Consolidated
Metric Name
Employee Fatalities
Lost Time Injury
Incident
rate for Employees
OSHA Recordable
Cases
Incidence Rate for
Employees
Contractor
Employee Fatalities
Process Safety
Incidents
Process Safety
Total Incident
Rate (PSTIR)
Hazardous Waste
for
Disposal
Non-Hazardous
Waste
for Disposal
Quantity of Waster
Water
discharged to
Environment
Discharges to Water
Chemical Oxygen
Demand
Process Water
Consumption
Performance Metrics - 2010
Assigned PM Key
A1
A2
A3
A4
B1
B2
C1
C2
C3
C4
D3
M-02
0
0.08
0.41
0
0
0
20,840
453
0
0
3.03
M-03
0
0
0
0
0
0
15.98
31.20
76,530.50
NR
0.18
M-04
0
0.705
1.41
0
NR
NR
0
592
128,604
NR
1.7073
M-05
0
6.07
0.21
0
0
0
140
120
109,000
1.7
0.331
M-06
0
0
0
0
2
0.42
91
250
526,220
7.48
0.684
M-07
0
0
0
0
0
0
301.7
206.6
334,103,112
20,046.2
1.606
M-08
0
2.45
0.22
0
NR
NR
110.28
28
642,204
NR
1.15
M-10
0
0.036
0.14
0
0
0
223.388
139.008
1,473,660
177
4.46
M-11
0
0
0
0
15
0.08
342
656
912,300,856
79
2.87
M-13
0
0.22
1.16
0
0
NR
143.43
445.4
1,270,200
29.72
2.08664
M-16
0
0
0.42
0
NR
NR
227
62
NR
152
1,116,216
M-17
0
0
0.32
0
NR
NR
142,122
6,188
2,086,555
156.5
4.37
M-18
NR
0
0.28
NR
0
0
1,308
616
47,249
NR
1.09
M-19
1
0.20
0.26
4
8
0.15
377,544
100,289
5,892,925
133,360
44.37
M-20
0
6.03
0.26
0
NR
NR
34,667
222.5
0
0
7.2
M-21
0
0
0.07
0
NR
NR
4,919
1,802
0
0
7.44
M-23
0
0.00
0.00
0
NR
NR
576
268
0
0
1.53
M-25
0.0
0.0
0.0
0.0
NR
NR
18654
0.0
0
0.0
1.53
M-26
0
0
0
0
0
0
1460
0
0
13.92
0.69
M-29
0
0
0.2086
0
0
0
748
888
380,454,181.5
0
8,423.6
603,856
112,989
1,639,111,297
154,023
1,124,726
Full Members
6
Total
Legend:
NR - NOT REPORTED
Comments
7
2010 EH&S Data Received
Phase I Submittals
90
Required
Reported
97.5%
80
93.75%
70
60
80
50
78
80
75
40
30
57.5%
40
20
23
10
0
Occupational safety (6)
20 / 24 companies participated
8
Process Safety (3)
Emissions/Discharges (6)
2011 EH&S Data Received
Phase II Submittals
100 %
120
Required
93.8%
Reported
100
114
80
114
114
107
96.5%
60
80.7%
57
40
57
55
46
20
0
Occupational safety (6)
19 / 24 companies participated
9
Process Safety (3)
Emissions/Discharges (6)
Resource Utilization (3)
2010/2011 EH&S Data Received
400
350
Required
94 %
Reported
300
250
342
88 %
200
150
100
200
322
176
50
0
2010 Phase I
10
2011 Phase II
Occupational Safety
11
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
12
Occupational Safety Definitions
•
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
13
GPCA Member Company, Occupational Safety Data Set Analysis
(TRIR=Total Recordable Incident Rate)
Arithmetic AVG.* = 0.27
7 Reporting Zero
*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
Actual AVG. TRIR = 0.17
Arithmetic AVG. * = 0.426
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
2010 and 2011 Occupational Safety Performance
Benchmarks
16
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)
17
Occupational Safety
Panel Q&A
18
Process Safety
19
Process Safety – Value of Metrics
•
Are important to stakeholders
•
Provide a measure to benchmark across industry
•
Demonstrates performance improvements
20
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:
21
1.
An employee or contractor LTI, and/or fatality, or hospital admission and/or
fatality of a third party (non-employees/contractor).
2.
An officially declared community evacuation or community shelter-in-place;
3.
Fires or explosions resulting in greater than or equal to $25,000 of direct cost
to the company, or;
4.
An acute release of flammable, combustible, or toxic chemicals greater than
the chemical release threshold quantities
Process Safety Definitions ……Cont.
•
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) severityweighted 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
22
What Is Severity Level?
Consequences of PSI Incident
Severity Level from
CCPS Table 2
Recordable Injury to Employee or Contractor
4
Lost Word Day ( Lost Time) Injury
3
Fire or explosion resulting in direct cost 100,00 to 1 Million $
3
On Site Fatality employee or contractor
2
Fire or explosion resulting in direct cost > 10 million $
1
23
GPCA Member Company, Process Safety
Data Set Analysis
2011 Number of Process
Safety Incidents
25
Not Reported : 8
9 reporting zero
Not Reported: 3
9 reported zero
20
15
10
5
0
0
2
4
6
8
10
12
14
16
18
20
Key Messages: Wide variance in numbers reported indicate understanding needed on definitions &
Data capturing.
24
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.
25
Process Safety
Panel Q&A
26
Environmental Emissions/Discharges
27
Emissions and Discharges
Value of Metrics:
28
•
Hazardous and Non Hazardous Waste for Disposal: primarily a measure for the
efficient use of resources
•
Discharge to Water - Quantity & Chemical Oxygen Demand: reflects the potential
adverse impact on the aquatic environment
•
Sulphur Oxides (SOx) and Nitrogen Oxides (NOx): This core measure is identified in
the Responsible Care Global Charter.
•
It is important to external stakeholders and relatively easy for members to report.
•
It is a regulatory requirement in most areas.
•
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
29
Environmental Data Reporting – 2010 & 11
Environmental Data Rquired
120
100
80
60
40
20
0
Reported Data inputs by GPCA Members
82 %
85 %
80
94
68
2010
30
114
2011
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
31
Environmental Emissions & Discharges
Panel Q&A
32
Resource Utilization
33
Resource Utilization
Value of Metric:
•
•
34
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.
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.
35
Resource Utilization - Data Set Analysis
60
50
94.7 %
Data Inputs Required
Data Inputs Reported
57
40
54
30
100 %
20
10
20
20
0
2010
2011
Key Message: Data Sets with huge variations demands a better understanding of metrics definitions.
36
Resource Utilization
Panel Q&A
37
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.
38